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Tumolo’s Toolbox

7 Step Improvement Process. Tumolo’s Toolbox. Elements of process improvement and control. Every process has three (3) elements 1. The area of discovery Understanding the customer requirements and developing the process to meet these requirements

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Tumolo’s Toolbox

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  1. 7 Step Improvement Process Tumolo’s Toolbox

  2. Elements of process improvement and control Every process has three (3) elements 1. The area of discovery Understanding the customer requirements and developing the process to meet these requirements 2. The method of process control Assessing performance and variation 3. The element of improvement Problem solving and quality improvement

  3. Process Improvement Opportunity or Problem Identification 7 Step Improvement Process Process Control

  4. the in innovation insight invention inspiration intuition instinct prayer clairvoyance Copy Imitation consultation Benchmark Other world Inner self Improvement or Problem others delegation negotiation just waiting passing-the-buck confusing finger pointing transferring real world gut feel systematic PDCA 7 Steps random trial-and-error guess accident chance luck

  5. 7 QC Tools PDCA 7 STEP Check sheet, graph, Histogram, scatter diagram, Pareto diagram, cause-and-effect diagram, flowcharts Flowcharts Check sheet, graph, Histogram, scatter diagram, Pareto diagram, cause-and-effect diagram, run chart/control chart Flowchart 1. Select a Theme 2. Collect Data 3. Analyze causes/opportunities 4. Plan and implement solution / improvement 5. Evaluate effects 6. Standardize 7. Reflect on process PLAN DO CHECK ACT (provides repetition) (provides process) (provides tools)

  6. 7 Step improvement process • Focus on weakness • Thoroughly explore the problem/opportunity • Carefully select the theme • Clearly state the theme • Have weakness orientation • State as a problem/gaps, not a solution • State in terms of results 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process

  7. Selecting the theme • Weakness is difference between current situation and the target. • Weakness orientation focuses on eliminating weakness as basis • of improvement (Closing the Gap). } } Customer Need Current Weakness Weakness Actual Performance Target Focus on facts, processes, and root causes

  8. 7 Step improvement process • Define your data collection process • Appropriate to process • Multi-variable data • Analyze the data • Stratification • Graphics • Focus on deviation • Draw a logical conclusion • Based on facts • Focus on vital few 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process “Primary tool used is Pareto Diagram

  9. Frequently used data collection tools Used to systematically collect data or tabulate data. (e.g. frequency of occurrence of defect types) Excellent method to identify vital few. (2 levels minimum) (e.g. Percent of failures due to various defect types arranged in descending order of occurrence) Method to identify non-standard process variation (e.g. Solder paste height versus time) Method to identify trends in data (e.g. In circuit test yield versus time) Method to identify distribution of the data (e.g. Number or solder paste observations falling into various height ranges) CHECKSHEET PARETO DIAGRAM CONTROL CHART GRAPH (RUN CHART) HISTOGRAM

  10. 7 Step improvement process • Create cause-and-effect • diagram from Pareto • Investigate cause thoroughly • Draw logical conclusions • (i.e. supported by data) 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process Ask Why?5 times

  11. 100% 2nd why 4th why Methods Material Pareto Diagram 5th why 3rd why 1st why A Man Machine Cause effect Diagram A B C D E F • ASK 5 WHYS to get to the proper level of analysis and causes. • Segment by 4 Ms • Man • Machine • Methods • Material

  12. Verifying Root Causes Collect data on root causes Use run charts, Pareto, Graphs, scattergrams, etc. to determine strength of correlation between root cause and problem If verification fails to validate choices, return to diagram and choose new root causes to verify.

  13. 7 Step improvement process • Focus on the primary root causes • Focus on solution which you can • implement • Dont try to fix everything at once • Involve those who will be affected • Run a controlled experiment (Pilot) 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process

  14. = LOW = HIGH = MEDIUM Solectron Criteria Feasibility Effectiveness Total Score A tool to help determine which solution is best. Solution 1 Solution 2 Solution 3 Solution 4 ------- Scoring values Possible score 3 or 2 or 1 values 6 3

  15. A tool to help determine ease or difficulty in solving specific problems. Area of Problem Equipment Methods Human Behavior You You and Others Others Easy Easy Difficult Data Collection/ Potential solution implementation Moderately Moderately Very Difficult Difficult Difficult Very Difficult Difficult Difficult

  16. Solution Implementation What When Where Who How How will they get it done Who is responsible for doing it Where will it be done When will it be done What will be done

  17. 7 Step improvement process • Confirm improvement • (Before and after comparison) • Evaluate all subsequent effects • Measure improvement gains over • time 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process

  18. } Original Pareto “BEFORE Improvement New Pareto “AFTER 100% } Pareto Diagram Effect on Root Cause “Fewer defects A B C D E F

  19. 7 Step improvement process • Move from PDCA to SDCA cycle • Revise the standard • Create a process to detect future • problems 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process

  20. Standardization PDCA SDCA New Std Do Std Do Plan Act Act Check Check Control Improvement

  21. 7 Step improvement process • Analyze strengths and weaknesses • Determine the next problem • Document the Quality improvement • story • Identify the critical difficulties during • the process - using tools, etc. • Identify the critical strengths • Identify the key things the team • would do differently • Identify what key things the team • needs to learn to improve the 7 step • process. 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process

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