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Survey of Tactical Methods

Survey of Tactical Methods. XONITEK Consulting Group Int’l Friday, August 13, 2010. Six Sigma Frameworks / Charting. The PDCA Framework. Classic concept from W. Edwards Deming in quality management Plan Determine “what” to improve and “how” to accomplish the change Do

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Survey of Tactical Methods

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  1. Survey of Tactical Methods XONITEK Consulting Group Int’l Friday, August 13, 2010

  2. Six Sigma Frameworks / Charting

  3. The PDCA Framework Classic concept from W. Edwards Deming in quality management Plan • Determine “what” to improve and “how” to accomplish the change Do • Implement the change Check • Are the results as expected? Act (or Adjust) • Go back and make changes to achieve the desired result Iterate the PDCA process for continuous improvement Presented by XONITEK Corporation

  4. The DMAIC Framework The Six Sigma evolution of PDCA Define • What is the problem or opportunity? • Based on the Voice of the Customer and internal goals Measure • Collect data relevant to the goals of the project Analyze • Analyze the data, to determine root cause of deficiencies Presented by XONITEK Corporation

  5. The DMAIC Framework Improve • Implement changes • Might involve pilot testing, Design of Experiments, etc. Control • Implement measures to ensure the new process is consistently applied (Standard Work) • Ensure control measures are in places, such as Statistical Process Control (SPC) There is a similar framework for new product development (DMADV) Presented by XONITEK Corporation

  6. The SIPOC Framework Process Step 1 Step 2 Step 3 … Suppliers Input Output Customers Very useful in conjunction with high-level Value Stream Maps Excellent way to take a “first pass” at process structure Presented by XONITEK Corporation

  7. The Normal Curve… B • Data points are symmetrical around the “mean”, the center of the curve. • The width of the curve demonstrates the extent of the variation. A D C E F XONITEK Corporation

  8. A Normal Curve over a Histogram… • This is a curve fitted over a Histogram from Minitab. • The Mean or Average is 5.889. • The standard deviation is1.928. • Number of sample data is27. XONITEK Corporation

  9. Data Types Continuous Data • Can take on any value (12, 12.55, 12.5599218430…) • Examples: Database response time, bus run duration • Charts: XmR, X-bar,R, X-bar, S Discrete / Attribute Data • Can take on a value only from specific choices (True/False, Red/Yellow/Green) • Examples: Query succeeded or failed, driver reported for shift or did not • Charts: np, p, c, u Presented by XONITEK Corporation

  10. Source: Lean Six Sigma Service Excellence, p. 87

  11. Sample Xbar-R Chart Upper Spec Limit Lower Spec Limit XONITEK Corporation

  12. Control Chart Interpretation If control limits are within specification limits, process is likely to be “within control” Common cause variation is within acceptable limits If not, consider a Six Sigma project to improve the process Presented by XONITEK Corporation

  13. Control Chart Interpretation Visual inspection of the chart can indicate potential problems within the process: • Points outside the control limits • A gradual shift of the process mean • A trend up or down in values • Non-random cycles • Etc. Control chart violations typically point to potential special cause variation Presented by XONITEK Corporation

  14. Key Measure: Process Capability 1.33 ≤ Cpk ≤ 2 Process is capable of consistently delivering to customer specification Cpk = 2 Six Sigma performance Presented by XONITEK Consulting Group Int’l

  15. Six Sigma Frameworks / Charting *** Questions and Discussion ***

  16. Quality Function Deployment (QFD)

  17. Typical product development process... • A company crisis prompts action… • Angry customer • Hot selling product/service from competitor • Obsolescence • Negative Reactionary Impacts • Poor selling dud • Hot selling, but defective • Lots of development but no product/service Presented by XONITEK Corporation

  18. When should you use QFD? • Incremental Innovation • Making improvements to an existing service • (Easy to gather customer needs) • Operations Planning • Matching a set of equipment/operators/IT resources to a set of product families/service offerings • Human Resource Strategy • Comparing current employee skillsets to the results of a strategic planning process Presented by XONITEK Corporation

  19. The QFD Approach, Step 1 • Identify the Customer • External • Market segment? • Use profile? • Key success factors? • Internal • Why is this product/process needed? • Is it really valuable to meeting external customer demands? • Establish the project team! Presented by XONITEK Corporation

  20. The QFD Approach, Step 2 • Gather Needs Data • Surveys • Focus Groups • Studies • Complaints • The Blogosphere • Your competitors’ products Goal: Product features + relative importance Presented by XONITEK Corporation

  21. The QFD Approach, Step 3 • Organize the Input • Affinity Diagrams Find key concepts • Tree Diagrams Identify Cause and effect • Pareto Charts Quantify results for factors Be careful not to “bias” the results; Ensure this is really the customers’ voice. Presented by XONITEK Corporation

  22. The QFD Approach, Step 4 • Build the QFD, incorporating… • Customer needs • Design requirements • Ability to deliver on requirements • Competitors’ performance Examples to follow… Presented by XONITEK Corporation

  23. How the QFD is Built…. Design Correlation Table The elemental structure of the house… Design How’s Or Company offerings Category Header Customer and Competitor Ratings Customer “What” Or “Needs” Customer and Engineering/Company Relationships Technical Ranking Technical Values for Objectives Presented by XONITEK Corporation

  24. Building the Relationships… 2 Develop the relationship between a customer’s Needs and a Gym’s Offerings…. The Customer Needs are derived from interviews and surveys…. Company Offerings 1 Customer Needs First list the customer needs and the company offerings 1 2 XONITEK Corporation

  25. Correlate the Customer and Company… Establish the strength of the relationships between the Wants and the Needs conveyed using symbols… 3 3 XONITEK Corporation

  26. Define Customer Significance & Competitor Benchmarks... Customer Significance to each “Need” should be noted. The Competitors’ positions with regards to those needs. If there are “selling” points based on these comparisons they should be denoted. 1 1 2 2 3 3 XONITEK Corporation

  27. Establish the “Relationship” of the Offerings… Very Strong Relationship Strong relationship Establish strength of the Design or Offerings relationships to each other…. Weak relationship Program times Maint.. schedule Fitness staff Facility size Staff schedule Training Fee structure Maint. staff Access control Amt./types equip. Instructions Facility hours Internet access Program offerings Lighting XONITEK Corporation

  28. Establish the Technical Values and Rankings… List the Competitors’ technical ranking. Establish your own targets for offerings. Identify the most critical actions that you need to undertake to satisfy the customer. 1 2 3 1 XONITEK Corporation 3 2

  29. Quality Function Deployment (QFD) *** Questions and Discussion ***

  30. Failure Mode and Effects Analysis (FMEA)

  31. FMEA XONITEK Corporation A way to conduct a “reliability analysis” of a product or service A systematic look for: • Function • Failure causes • Failure modes • Failure consequences

  32. Types of FMEA activities XONITEK Corporation DFMEA – Design analysis of: • Components • Subsystems • Main systems PFMEA – Process analysis of: • Equipment • Scheduling • Workstations • Gages • Procurement • Employee training • Tests

  33. FMEA Reference Form Sample FMEA form… XONITEK Corporation

  34. FMEA Header Data XONITEK Corporation FMEA Title – Name of the System, Subsystem, Component or Process… FMEA Type – Circle or otherwise highlight if this is a Design or Process project. Project Leader – Person responsible for the FMEA overall… Prepared By – Individual maintaining updates on the project. Project Description – Concise and easy to understand description of the function… • Include any additional technical parameters to help define the failure modes…

  35. FMEA Header Data XONITEK Corporation Dates: • Original Date – the date the FMEA was created. • Revised Date – this is the date the input from various persons was added to the file. • Key Date – the targeted completion date of the project. Core Team – Members of the team responsible for the development of the FMEA and various aspects of its completion.

  36. Current State Section XONITEK Corporation Item or Function – Identifies the various parts, processes or subsystems that may fail. • Use Brainstorming to begin to identify these elements of the FMEA. • Man, materials, design, process, environment. • Fishbone Diagrams may be useful to “get to” the root causes. Potential Failure Mode – Describes how the process or design may fail to perform with regard to design or process parameters… • Can be a list of separate failure modes for the same functions • May reference the upper or lower assembly impacts… Potential Effects Mode – Describes the impact of the failure with regards to the customer (internal or external)… • “If – Then” consequential statements. Classification – Optional information, used when Govt. Regs., Safety Considerations or Engr. Specs exist for the product or process… • Use a key for this field and add to the FMEA form to clarify symbols.

  37. Severity Rating Scale • Severity Rating – Scale of 1 to 10 created by the team… with 10 as the most severe. XONITEK Corporation

  38. Current State Section XONITEK Corporation Potential Causes of Failure – Descriptive and comprehensive list of all “root” causes of failure… • Reference “Fishbone” diagram as one of the tools to find this cause… • Each “potential failure mode” may have more than one cause of failure. OccurrenceRating – An estimate of the frequency of the failure… derived from a team created table… • Occurrence ranking shown on next slide…

  39. Occurrence Rating Scale XONITEK Corporation

  40. Current State Section XONITEK Corporation Current Controls Prevention – Identify the methods and testing parameters that exist to find this failure... Current ControlsDetection – Defines the manner that the defect is identified… • Preference is detection by use of SPC or other testing methods. • Discovery by failure is NOT preferred… DetectionRating – User defined table with assigned probabilities and associated rankings… • Ranking table guide in next slide…

  41. Detection Ranking XONITEK Corporation

  42. Current State Section XONITEK Corporation Risk Priority Number(RPN) – A value to rank the concerns calculated from the multiplication of the other rankings … • RPN = Severity x Occurrence x Detection (the product of these three values) • Use this value to prioritize the actions and resources of the organization. • Do not overstep your resource capabilities… set a threshold of items for action and focus on those items first. • Items with lower numbers but still have high severity must be addressed… Recommended Actions – Actions taken to lower the RPN… includes Cause and Effect diagrams, control charts or other actions necessary to reduce the risk tied to the RPN…

  43. Actions to RPN XONITEK Corporation Develop a strategy of what items to address in what order… • Look for “synergy” of activities, where multiple problems may overlap. • If you can’t eliminate the issue find ways to make it easily detectable when it occurs. • Reduction of “severity” or “occurrence” is preferred over making the failure more detectable. Document all process or design changes and their impacts as part of the report out methodology. • Recalculate the RPN as improvements are made to re-establish priorities.

  44. Details of filling out the FMEA XONITEK Corporation Person Responsible and Due Date – Enter the name of the person who has the lead action and target date of completion… Actions Taken – Describe the action and implementation date… Severity/Occurrence/Detection – The revised values based on actions taken… RPN – Revised RPN recalculated (multiply the three values: Severity, Detection and Occurrence) from the values above…

  45. Sample Completed FMEA XONITEK Corporation

  46. Failure Mode and Effects Analysis (FMEA) *** Questions and Discussion ***

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