Lean Six Sigma 4 - Pan Learn

1. Measure Phase- Cause and Effect Tool  The Cause and Effect tool is used in determining the critical course inputs that have the greatest impact or effect on the overall course performance. Since the table comes with weights that help calculate the inputs, it is then easier to identify which amongst all inputs gives greater impact on the course. All inputs indicated in the high level process map should be included in the cause and effect table. In the same manner that all output requirement in the SIPOC table should be included in the Cause and Effect table: www.panlearn.com

2. Six Sigma DMAIC – Analyze Phase This is where the statistical study of a problem starts. In this phase statistical reviews are done to the groups of deviation or variation for project owners to identify which are the considerable contributors to the output. The focal point of this phase is to identify and analyze the root cause/s of imperfection. This phase consists of several steps which also require several tools. The phase usually starts by organizing the experimentation schedule to identify which of the potential KPIV’s (key performance indicator variables) is the real origin of defects. Enough data is also required, and this set of data will be analyzed using an appropriate statistical procedure. www.panlearn.com

3. Analyze Phase - Ishikawa Graph.  The most common tool used in this phase is the fishbone diagram also called the Ishikawa graph. This is a graphical demonstration of possible problem causes. The chart will show the association of cause and effect. The advantage of using this tool is that it stimulates the reasoning during brainstorming activity of possible causes. It gives visual presentation of possible causes. The possible causes are grouped, therefore reducing the chances of omitting some possible causes. And since the causes are charted, project owners will see and understand the relationship between possible causes. Constructing a fishbone diagram is not that easy. Since this is done during a brainstorming activity, conflict of ideas and opinions are always expected. The good thing is that the outcome is always reliable and sound.  www.panlearn.com

4. Box Plot or the whiskers plot • Another tool used in analyze phase is the box plot or the whiskers plot. This is fitting to use if the data sets are as few as ten – twelve values. However, this is not suitable if sample size is less than ten. This gives a graphical review of a data set showing the measure of middle location, two measures of spreading, the skewness, and the outliers. Outliers are known as the values that don’t seem to be part of the standard data. The box displays three values: the median (Q2), the lower quartile (Q1), and the upper quartile (Q3). Extending from the box are lines also known as the whiskers which lengthens to the maximum and minimum value. • To create a box plot, several values must be computed. These are: • Quartile One (Q1) – is the average of the lowest twenty-five percent of the data set • Quartile Three (Q3) – is the average of the highest twenty-five percent of the data set • Maximum (Max) – is the biggest value amongst all data set • Mean – is the standard value • Median – is the center value of a data set • Minimum (Min) – is the least value amongst all data set • Inter Quartile Range (IQR) – using the formula Q3-Q1, this is the middle fifty or the mid spread • Outlier Low – using the formula Quartile One – 1.5 * Inter Quartile Range or higher than • Outlier High – using the formula Quartile Three + 1.5 * Inter Quartile Range www.panlearn.com

5. Creating a Box Plot • To create a box plot, several values must be computed. These are: • Quartile One (Q1) – is the average of the lowest twenty-five percent of the data set • Quartile Three (Q3) – is the average of the highest twenty-five percent of the data set • Maximum (Max) – is the biggest value amongst all data set • Mean – is the standard value • Median – is the center value of a data set • Minimum (Min) – is the least value amongst all data set • Inter Quartile Range (IQR) – using the formula Q3-Q1, this is the middle fifty or the mid spread • Outlier Low – using the formula Quartile One – 1.5 * Inter Quartile Range or higher than • Outlier High – using the formula Quartile Three + 1.5 * Inter Quartile Range • Six Sigma has two key methodologies − • DMAIC − It refers to a data-driven quality strategy for improving processes. This methodology is used to improve an existing business process. • DMADV − It refers to a data-driven quality strategy for designing products & processes. This methodology is used to create new product designs or process designs in such a way that it results in a more predictable, mature and defect free performance. • There is one more methodology called DFSS − Design For Six Sigma. DFSS is a data-driven quality strategy for designing or redesigning a product or service from the ground up. Common rule is that, the smaller the box and the shorter the whiskers, the better. This means that values are close to each other. Defect can easily be detected. www.panlearn.com

6. Scatter plot or scatter diagram Scatter plot or scatter diagram is another tool used to analyze a given set of data. This evaluates the influence of one value to another. This graph includes two different sets of variables represented on two different axes, the horizontal axis and the vertical axis. This diagram gives two types of information. Visually, we look for outlines that the two sets of data related to each other. If the two sets of data are related to each other, we then identify in what way they are related. The relationship amongst two variables is known as the correlation. Correlation is identified with the use of quadrants. www.panlearn.com

7. Six Sigma DMAIC – Improve Phase The focus of this stage is to determine a solution which is based on the uncovered problem in the first three phases. This phase requires realization of the KPIV’s that are causing the outcome. The activity requires three things: brainstorming by project owners and members whose goal is to create a solution that will address the main problem, Testing the solutions, and Assessing the outcome of the executed solutions. This stage will help conclude the amount and relationships of identified variables to the project Y. Most of the time before rolling-out a full-scale implementation, project owners conduct test run on a sample group. This is done to determine the finest settings. It is logical to choose the most effective setting which is also factored on the company’s resources, procedures and policies. Common tools used n this phase are the Seven Deadly Wastes, Five S, Benchmarking, and the Solution Selection Matrix. www.panlearn.com

8. The Seven Deadly Wastes The Seven Deadly Wastes corresponds to the areas that should be focused on when making an improvement. The areas considered in the Seven Deadly Wastes are: Overproduction Time/Waiting Defects Process Inefficiency TransportationInventory Motion www.panlearn.com

9. Improve Phase – Five S Implementation is the focus of Improve phase. Some project owners use the concept of Five S to create visual control on the work place. This methodology aims to improved safety, quality, and efficiency. The effect therefore is reduced cost and waste, and improved management. The approach is called the Five S because of a very plain idea. All five actions start with a letter S. Sort Set in Order Shine Standardize Sustain www.panlearn.com

10. Improve Phase – Benchmarking Tool Benchmarking is another tool that can be used during the Improve phase. This is a procedure used to calculate various characteristics of a certain process in relation to the most excellent practice. This permits the group to develop strategies on how to implement such best practice, typically with the intention of increasing some characteristics of performance. • Benchmarking vary on types: • Process benchmarking • Financial benchmarking • Performance benchmarking • Product benchmarking • Strategic benchmarking • Functional benchmarking www.panlearn.com

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