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Project Title. GB or BB name: XYZ. Define Phase. C. I. A. M. D. D. M. A. I. C. Deployment. D. M. A. I. C. Project Charter. D. M. A. I. C. Team. D. M. A. I. C. Gantt Chart. D. M. A. I. C. Framing Worksheet. D. M. A. I. C. Customer Requirements CTQ’s. D. - PowerPoint PPT Presentation
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Project Title
GB or BB name: XYZ
Define Phase
D M A I C
Deployment D M A I C
Project Charter D M A I C
Project Logo or SOA
Date:
1.2. Department & Machine involved 1.4. Weekly Meeting on: (day & time)
Planning
Plan / DMA: ?? Do/ I: ??
Check / C: ?? Act / C: ??
7. Team and Stakeholder Signatures 6. Controller Verification of Savings
5. Quantitative Objectives of the Project (to be achieved with the full implementation of all countermeasures)
6. Potential Savings (000$/year)
3. Project Description: (methods/tools to be used)
4. Project KPIs
2.1. Team members involved (names) 2.2. Internal and / or External Customer
Project Title
1.1. Project Title1.3. Problem description (What problem / Why is it a problem)
Team D M A I C
Name Function Role In the team In charge of…
Gantt Chart D M A I C
Framing Worksheet5W+2H (Operational Definition) [Plant Name][Project Name][Brief Project Description][Date]
Description of Problem
IS IS NOT
WhoCustomer Name
Location
WhatProductProcessSystem
WhenFirst Seen
When else seen(dates, events)When seen in
product life cycleWhere
On objectGeographically
WhySupportive Data
HowProcess Conditions
How Many# of Defects
# of Parts# of Concerns
Trends
D M A I C
Customer Requirements CTQ’s
VOC
for example:
Key Issues Customer CTQs
Measurable Requirements
1st level
Customer CTQs if needed
2nd level
1 When I’m staying in a hotel I like a good bath
right temperature Temperature > 30 degrees
< 36 degrees
Fills up quickly time to fill < 5 mins
2
3
D M A I C
SIPOC
Suppliers Inputs PROCESS Outputs CustomersUse nouns Use verbs Use nouns
Start point
Arrival point
For example
D M A I C
Measure phase
MD A I C
D M A I C
Current process map
Include some initial map of your process
Process Mapping [Plant Name][Project Name][Brief Project Description][Date]
START
END
STEP 1
NO
YES
STEP 2
STEP 2B
TESTRESULTS
D M A I C
Ys behaviorD M A I C
I-MR Control Chart [Plant Name][Project Name][Brief Project Description][Date]
Quality Characteristic Individual value of T3 - 2010Sample Size, n 1
k 3
CL, 2.278
UCL, 3.805
LCL, 0.751
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Ind
ivid
ua
l v
alu
e o
f T
3 -
20
10
Sample #
CL, 0.574
UCL, 1.877
LCL, 0.0000.000
0.500
1.000
1.500
2.000
2.500
3.000
3.500
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Ra
ng
e
Sample #
Cause & effect diagram to find potential Xs
Brainstorming - Fishbone analysis [Plant Name][Project Name][Brief Project Description]
[Date]
5 5 5
1 1 1
6 6 6
2 2 27 7 7
3 3 3
8 8 8
4 4 4
1 1 1
5 5 5
2 2 2
6 6 6
3 3 3
7 7 7
4 4 4
8 8 8
trouble
MAN METHODS MACHINES
PROBLEM STATEMENT
MATERIAL MOTHER NATURE MEASURES
what, who, where, when, how much, how
Methods
Measures
Machines
MaterialsMother Nature
Man
DEFECT
D M A I C
Data collectionD M A I C
Check Sheet [Plant Name][Project Name][Brief Project Description][Date]
Name:
Date:
Shift:
Defect
Stones
Blisters
Blank Tears
Baffle Match
Pressure Break
Totals
Shop 11 Shop 12
5
Shop 22 Shop 31 Shop 32Shop 21 Totals
5
Check sheet Pareto
Spaghetti Diagram (Flow analysis) [Plant Name][Project Name][Brief Project Description][Date]
Data collection planD M A I C
What How Who WhereMeasure Operational
definitionType of
measure – Y or Xs
Type of Data
Measurement tools
Sampling scheme and Frequency
Who is collecting the data
On which document - form
Measurement System Analysis
Potential source(s) of measurement variation checklist Yes/No Evidence
Is my measurement system repeatable? _______Will I get the same results if I make the measurement more than once?
Is my measurement system reproducible? _______ Will someone else be able to complete the same measurement & get the same results?
Is my measurement system accurate? _______Will the results from the study match the actual value or expert data?
The appropriate analysis tool to quantify the amount of variation due to the measurement system is
_______ Very simple assessment_______ Discrete data analysis tool (for repeatability, reproducibility & accuracy)_______ Gage R&R - ANOVA method_______ Gage R&R - Short method
Only if issues on Measuring system
Is the Measurement System adequate ______ Yes/No
D M A I C
Measurement System Analysis – Gage R&RD M A I C
Baseline process sigma
Number of units processed N = __________
Total number of defects made (include defects made and later fixed) D = __________
Number of defect opportunities per unit (equate to CTQs) O = __________
Calculate # defects per million opportunities DPMO = 1,000,000 x ( )
= 1,000,000 x
= __________
Look up process sigma in Sigma = __________ sigma conversion table
DN x O
( )
( ) ( )
(method 1)D M A I C
Baseline process sigma (method 2 – using Jmp)D M A I C
short term sigma = 0.74long term sigma value = 2.35
Stable or unstable ?
Analyse phase
MD A I C
D M A I C
Cause & effect diagram for Experience Door without data collection plan
D M A I C
Brainstorming - Fishbone analysis [Plant Name][Project Name][Brief Project Description]
[Date]
5 5 5
1 1 1
6 6 6
2 2 27 7 7
3 3 3
8 8 8
4 4 4
1 1 1
5 5 5
2 2 2
6 6 6
3 3 3
7 7 7
4 4 4
8 8 8
trouble
MAN METHODS MACHINES
PROBLEM STATEMENT
MATERIAL MOTHER NATURE MEASURES
what, who, where, when, how much, how
Methods
Measures
Machines
MaterialsMother Nature
Man
DEFECT
5 Whys Analysis for Experience Door without data collection plan
Catalyst Consulting Ltd. 2006
D M A I C
Brainstorming - 5 whys[Project Name][Brief Project Description]
[Date]
what, who, where, when, how much, how
Cause Why 1 Why 2 Why 3 Why 4 Why 5
1
2
3
4
5
6
7
8
9
10
PLAN
PROBLEM STATEMENT: Seal Star issues causing rework and overmanning
Statistical Analysis
Catalyst Consulting Ltd. 2006
D M A I C
Box plotScatterplotSimple regressionFit Y by XAnovaScreeningPartitioning…
Y=f(Xi) – Statistical ModelD M A I C
Vital few Causes
Critical X
1
2
3
4
D M A I C
Improve phase
ID M A C
D M A I C
Proposed solution D M A I C
Proposed solution D M A I C
add additional slides to elaborate on actions using pictures and summary activities
Control phase
CD M A I
D M A I C
32
D M A I C
ONE POINT LESSON (OPL)
Facility:Date Created: OPL Number:Author:OPL Category: Approver:Area in Facility: Approver Title:
OPL Description:
OPL
Control PlanD M A I C
Quality process control plan [Plant Name][Project Name][Brief Project Description][Date]
Indicators By whom?
Quality process control plan
When?Out of control actionwho is in charge?Control range
Final process sigma
Number of units processed N = __________
Total number of defects made (include defects made and later fixed) D = __________
Number of defect opportunities per unit (equate to CTQs) O = __________
Calculate # defects per million
opportunities DPMO = 1,000,000 x ( )
= 1,000,000 x
= __________
Look up process sigma in sigma conversion table Sigma = __________
DN x O
( )
( ) ( )
(method 1)D M A I C
Final process sigma (method 2)D M A I C
BEFORE AFTER
ROSS Control – the final outcome
Baseline Final
Performance
Project Y ZST
ZLT
Financial benefits
Cost ££
Revenue £
Cash £
Implementation costs £
Net Benefit £
D M A I C