lean six sigma academy practical assessment project template date:- project title: organization:...

Lean Six Sigma Academy

P R AC T I C A L A S S ES S M E N T P ROJ EC T T E M P L AT EDATE: -

Project title: <title of the project>

Organization: <name of your organization>

Project leader: <your name>

Belt level: <Black or Green Belt>

Revision date: <e.g. 28-09-2015>

© LSSA 2015 2

DMAICIntroducti on for th is template

Objectives of this presentation:

1. Certification by LSSA2. Project summary for your organization

Guidelines:

• Methodology and logic understandable, for a Six Sigma trained external colleague

• Clear conclusions on each sheet

• Target for certification is max. 25 sheets (no limit for internal use)

• No back-up sheets

• Delete the (Italic) notes for the user, upon need

• Delete this slide before handing in.

© LSSA 2015 3

DMAICProcess improvement roadmap

DMAIC roadmap

• Define 1 Define and Scope project2 Define defect and CTQs3 Plan and document project

• Measure 4 Evaluate measurement system5 Establish baseline6 Set improvement goals

• Analyze 7 Map process and identify inputs8 Isolate key inputs9 Develop Y=f(X) function

• Improve 10 Determine optimum settings11 Implement proposed improvement12 Validate proposed improvement

• Control 13 Implement control strategy14 Close out project

© LSSA 2015 4

DEFINE1 – Defi ne and scope project

Problem Description:

Objectives:

What is wrong, how does it affect the customer, what is the pain for the organization? Is it a priority, so in line with top-down priorities?

Add picture or drawing to explain(If ready, delete this textbox)

What do we want to achieve?Helicopter view description.(delete this textbox)

© LSSA 2015 5

DEFINE1 – Defi ne and scope project

In Scope

Out of Scope:

Deliverables:

Soft Benefits:

Hard Benefits:

Target: Describe the quantified, measurable result (not the solution!).What is the required timing?

What are the boundaries of the process to analyze; what are you allowed to change?

What not . . . ?

What evidence to put at the table to show that targets metrics are met?This is the key element in the agreement with the champion

Summarize the calculation to shows that this is a ‘major cost saving or cost avoidance, in keuro/year. Upon need add a separate sheet

Any nice additional benefits, like customer satisfaction, learning Six Sigma

© LSSA 2015 6

DEFINE2 - Defi ne defects and CTQs

CTQ ext

Start from customer perspective

Variable: ……… Conditions: …… Target: ………… CTQ int

CTQ extVariable: ……… Target: ………… Specifications: ……

‘OK for customer’

Customer specification

Internal specification

Describe the measurable variable and specifications as defined in own organisation. Can be different from the CTQext, but must have a known/proven relation with CTQext.

Describe the measurable variable and specifications as required by the customer.

This can be a vague description of the critical variable

High level, describe until highest level measurable CTQ int. (the project target)

Legend: solid line: proven relationdotted line: relation tbd.grey box: out of scopewhite box: potential CTQ, or group of CTQs

© LSSA 2015 7

DEFINE3 – Plan and document project

Project TeamSupplier: Champion: User: MBB:

Project leader (Belt):

Name: Role: Responsibility:

who provides resources driving for success will benefit from the results coach for methodology

Actively involved members in team meetings

© LSSA 2015 8

DEFINE3 – Plan and document project

SIPOC Process MapOutputs: Customers:

Supplier: Inputs:

‘Process’

Output variablesMain noises

Standard Operating Procedures

Controllable variables + specs

Process:

Step 1 Step 2 Step 3 Step 4 Step 5

If helpful show below detailed steps on the process

SIPOC is mandatory for process improvementFor design improvement: visualize product problem area

© LSSA 2015 9

DEFINEAssessment

Self Assessment

LSSA Assessor Feedback

Missing

Incorrec

tCorrect N/A

Define

1 Project addresses a clear problem or business opportunity (€20,000.- p/year). 2 Problem description has been clearly defined. 3 Goals have been clearly defined. Project objectives are measurable. 4 VOC and VOB have been defined clearly. Requirements have been understood. 5 Scope of the project has been clearly delineated. 6 Key stakeholders have been involved and informed. 7 Belt has shown to be able to manage the project adequately. 8 Project has been completed within time and budget.

Missing

Incorrec

tCorrect N/A

Define

1 Project addresses a clear problem or business opportunity (€20,000.- p/year). 2 Problem description has been clearly defined. 3 Goals have been clearly defined. Project objectives are measurable. 4 VOC and VOB have been defined clearly. Requirements have been understood. 5 Scope of the project has been clearly delineated. 6 Key stakeholders have been involved and informed. 7 Belt has shown to be able to manage the project adequately. 8 Project has been completed within time and budget.

© LSSA 2015 10

MEASURE4 – Evaluate measurement system

For Target internal CTQ’sEvaluate whether measurement error for the CTQ int, described in the target is good enough for this project.

e.g. reference data, GR&R, bias, attribute agreement, etc.

Conclusion:

CTQ int Measurement error

© LSSA 2015 11

MEASURE5 – Establ ish basel ine

Conclusion:

How is the situation on the CTQ’s in the beginning of the project? (measured with the known error)e.g. results of capability & performance study

If historical measurement error is unknown, add a note.Visualize if possible, for instance in time.

© LSSA 2015 12

MEASURE6 – Set improvement goals

Final Target

Conclusion:

Evaluate whether the original target(s) are realistic. If necessary describe the rational why the targets are being adjusted.

© LSSA 2015 13

MEASUREAssessment

Self Assessment


Missing

Incorrec

tCorrect N/A

Measure

1 Relevant KPI's have been selected / CTQ-flowdown has been constructed. 2 High level process description has been made (e.g. SIPOC). 3 Data has been collected / selected properly. 4 The collected data has been proven to be representative for the project. 5 Quality of the data has been verified in an appropriate way (GR&R if applicable). 6 Historical data has been used to visualize performance over time (e.g. Time series). 7 Variation in the process has been considered (common cause or special cause). 8 Short term versus long term performance has been considered. 9 Performance against requirements has been checked (Ppk if applicable).

Missing

Incorrec

tCorrect N/A

Measure

1 Relevant KPI's have been selected / CTQ-flowdown has been constructed. 2 High level process description has been made (e.g. SIPOC). 3 Data has been collected / selected properly. 4 The collected data has been proven to be representative for the project. 5 Quality of the data has been verified in an appropriate way (GR&R if applicable). 6 Historical data has been used to visualize performance over time (e.g. Time series). 7 Variation in the process has been considered (common cause or special cause). 8 Short term versus long term performance has been considered. 9 Performance against requirements has been checked (Ppk if applicable).

© LSSA 2015 14

ANALYZE7 – Map process and identi fy inputs

Process Map

Conclusion:

(process step 1)

….

….

(process step x)

Output variable 1Output variable 2Output variable 3.............

Input variable 1 Input variable 2.............

Input variable 1Input variable 2.............



Use this format for process improvementFor design improvement use Boundary Diagram or Parameter Diagram , for the applicable function(s)

These should be the CTQ’s

© LSSA 2015 15

ANALYZE7 - Map process and identi fy inputs

Ishikawa Diagram

Defect

Measurement Machine Men

Methods Environment Materials

Advice: use Xmind or Freemind

Conclusion:

Create this diagram to complete and categorize the list of inputs

© LSSA 2015 16

ANALYZE8 – Isolate key inputs

Conclusion:

If a large number of inputs is identified, it is important to limit the analysis to a small set of important (key)inputs.

Tools include: Cause & effect matrix, screening (DOE), FMEA

© LSSA 2015 17

ANALYZE9 – Develop Y=f(X) functi on

Conclusion:

Tools: Anova, Regression, DOE, simulation, etc

© LSSA 2015 18

ANALYZEAssessment

Self Assessment


Missing

Incorrec

tCorrect N/A

Analyze

1 Process has been mapped in detail (e.g. Process Flow / VSM Current State). 2 Potential root causes have been identified properly. 3 Data has been collected and analyzed correctly. 4 Graphical and statistical techniques have been applied to investigate root causes. 5 Major root causes have been identified. 6 Conclusions have demonstrated strong evidence / statistically valid.

Missing

Incorrec

tCorrect N/A

Analyze

1 Process has been mapped in detail (e.g. Process Flow / VSM Current State). 2 Potential root causes have been identified properly. 3 Data has been collected and analyzed correctly. 4 Graphical and statistical techniques have been applied to investigate root causes. 5 Major root causes have been identified. 6 Conclusions have demonstrated strong evidence / statistically valid.

© LSSA 2015 19

IMPROVE10 – Determine opti mum setti ngs

Conclusion:

DOE, simulation, etc

© LSSA 2015 21

IMPROVE12 – Val idate proposed improvement

Conclusion:

Show the verification run compared to baseline that the Define conditions will be met.

© LSSA 2015 22

IMPROVEAssessment

Self Assessment


Missing

Incorrec

tCorrect N/A

Improve

1 Improved process meets the requirements of the VOC and VOB. 2 Risks have been assessed (e.g. pFMEA). 3 Resistance for change has been overcome / Risks have been mitigated. 4 Internal and external customers have accepted the new process. 5 Improvements have been proven to be successful. (Capability study if applicable).

Missing

Incorrec

tCorrect N/A

Improve

1 Improved process meets the requirements of the VOC and VOB. 2 Risks have been assessed (e.g. pFMEA). 3 Resistance for change has been overcome / Risks have been mitigated. 4 Internal and external customers have accepted the new process. 5 Improvements have been proven to be successful. (Capability study if applicable).

© LSSA 2015 23

CONTROL13 – Implement control strategy

Conclusion:

Show the verification run compared to baseline that the Define conditions will be met.

© LSSA 2015 24

CONTROL13 – Implement control strategy

Open actions• ….• ….

Documentation • Component drawings• Manufacturing specifications• Control plan• Engineering reports• FMEA• ..

Roles & responsibilities• ..

How is assured that all information is well documented for future success

What are the key roles & responsibilities to assure continued success

Actions and owners necessary to finish this project

© LSSA 2015 25

CONTROL14 – Close out project

Conclusions • ….

Recommendations• ….• ….

Lessons learned• ….• ….

For follow-up, next steps, or next projects

For colleagues, others

Relate this to the project objective, targets and deliverables

© LSSA 2015 26

CONTROL14 – Close out project

The realized benefits of this projects are:

Controller:Date, Name & Signature

-

Champion:Date, Name & Signature

-

LSSA MBB:Date, Name & Signature

-

Summarize final total savings, average per year

© LSSA 2015 27

CONTROLAssessment

Self Assessment


Missing

Incorrec

tCorrect N/A

Control

1 Evidence of 'In-Control situation' available and sufficient. 2 Measures have been put in place to monitor process performance. 3 Documentation has been updated (pFMEA, CP, SOP's). 4 Training has been performed for the new process. 5 Improvements have proven to be sustainable. 6 Project report has been completed. Lessons learned have been communicated. 7 Champion has been involved and signed the project. 8 Controller signed that project savings / benefits have been achieved.

Missing

Incorrec

tCorrect N/A

Control

1 Evidence of 'In-Control situation' available and sufficient. 2 Measures have been put in place to monitor process performance. 3 Documentation has been updated (pFMEA, CP, SOP's). 4 Training has been performed for the new process. 5 Improvements have proven to be sustainable. 6 Project report has been completed. Lessons learned have been communicated. 7 Champion has been involved and signed the project. 8 Controller signed that project savings / benefits have been achieved.

lean six sigma academy practical assessment project template date:- project title: organization:...

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