senior leader's seminar chapter 5 lesson 4. 2 lesson 4 improve the process

SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 2

Lesson 4

Improve the Process


Objectives

You will be able to understand:

• The advantages of continual process improvement

• The key activities associated with process improvement


ACT PLAN

DOCHECK

Improve the Process

1. Plan a change for improvement

2. Carry out the change on a small scale

3. Analyze and interpret effects of the change

4. Act on what was learned

5. Repeat step 1 with new knowledge6. Repeat step 2 and onward


The Batavia Incident

TargetLSL USL

60 70 80 9010 20 30 40

Offshore:Less variation

Batavia:More variation

50


Specifications as Goals

Target

Loss

(Bad)

No Loss

(Good)

Loss

(Bad)

Does not meet

customer

expectations

Meets

customer

expectations

LSL USL

Measure of quality characteristic

Does not meet

customer

expectations


Quality Loss Function

TargetLSL USL


Loss FunctionCurve

IncreasingValue Lost

IncreasingValue Lost


Continual Improvementand the Quality Loss Function

TargetLSL USL


B A

Distributions

A B C

Loss Loss Loss Loss LossA B C

Value LostIncreasing

Value LostIncreasing


Activity 4.1 Plan

ACT PLAN

DOCHECK

• Plan what changes might lead to improvements• Decide what data are needed• Determine how, when, and by whom data will be collected


Cause & Effect Diagram

Reducedweaponsassembly and delivery time

EnvironmentMaterialsPeople

Equipment Methods

Pre-assembledComponents

Fewer weaponstypes

GreaseViscosity

Bettertools

Skids &yellowgear

Assemblyjigs

Reliableelevators

Bettertraining

Improvedwatchbill

Better “C”schools

Assemblyprocedures

Weaponsmovement

Closer storagespaces

Better/fasterelevators

Lights&ventilation

Straight thruelevators

Bettertraining

Bettertraining

Trainingpriority


Activity 4.2 Do

ACT PLAN

DOCHECK • Gather or review baseline data• Make planned changes on a small scale• Gather data to determine what happened after the changes


Activity 4.3 Check

• Compare results of changes with what was planned• Determine whether changes led to improvements

ACT PLAN

DOCHECK


Activity 4.4 Act

ACT PLAN

DOCHECK

• Decide on changes• Make the changes• Standardize • Educate & train• Monitor the process• Repeat the cycle


PDCA Cycle & Process Improvement

ACT PLAN

DOCHECK

• Plan what changes might lead to improvements• Decide what data are needed• Determine how, when, and by whom data will be collected

• Gather or review baseline data• Make planned changes on a small scale• Gather data to determine what happened after the changes

• Compare results of changes with what was planned• Determine whether changes led to improvements

• Decide on changes• Make the changes• Standardize • Educate & train• Monitor the process• Repeat the cycle


Leadership Involvement

• Study & learn PDCA

• Actively participate in quality improvement

• Develop a TQL implementation plan

• Choose initial efforts that are:- Customer or mission-driven- Likely to succeed- Measurable- Designed with strategic intent


1.1 Clarify The Mission

• Train ESC• Build commitment in ESC• Write Implementation Plan

ESC QMBClarify the

Charter

Stable ?

4.4 4.1

4.24.3

PAT

Assistthe

QMB

TQL Teams & Activities

ID & Prioritize:1.2 Org’s Customers1.3 Customer Reqmts1.4 Significant Processes

2.1 Describe Processes Charter QMBs

• Assess the Organization• Develop Critical Mass• Create the Environment• Refine Mission• Improve the TQL Impl Plan• Support and Extend CPI

2.1 Describe the Process2.2 Simplify, &2.3 Standardize the Process

3.1 Determine Measures

3.2 Construct Control Chart

3.4 Check for Capability

3.3 Act on SpecialCauses

(only if required)

Task (or Charter)a PAT

• Help with Flow Chart• Collect data• ID & remove special causes• Provide ideas

No

Yes

(MOM 6)

PA

DC


Summary of Key Activities

Identify

Simplify &Standardize

Stabilize

Improve

1.1 Clarify the mission1.2 Identify & prioritize customers1.3 Identify & prioritize customer requirements1.4 Identify significant processes that meet customer requirements

2.1 Describe the process2.2 Simplify the process2.3 Standardize the process

3.1 Determine process measures3.2 Examine the process by using control charts3.3 Act on special causes3.4 Check for capability

4.4ACT

4.1PLAN

4.2DO

4.3CHECK


Chapter Summary

• Process improvement is a job for everyone

• Process improvement must be continual

• Process improvement affects organizational systems

• You are responsible for leading process improvement


Summarize YourResponsibilities forImplementing TQL

senior leader's seminar chapter 5 lesson 4. 2 lesson 4 improve the process

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