IMPROVE PHASE

Topics covered:
1. Idea / Solution Generation
 Brainstorming, Subject Matter Expert
 Process Flow Diagram
 Hypothesis Tests – r , r square, linear equation etc.
2. Screening of Ideas / Solution
3. Risk Management - FMEA
4. Pilot Testing
 Update Action plan & FMEA
 Validation of improvement
 Cost Benefit Analysis – Full scale improvement approval
5. Full Scale Implementation
 Update Action plan & FMEA
 Validation of improvement on full scale
 Cost Benefit Analysis
 Before & After Analysis
Screening Solutions
1. N/3 Voting Technique
2. Nominal Grouping Technique
3. Efforts Benefit Matrix
4. Cost Time Matrix
5. Quality Function Deployment (QFD)
(X & Y relationship matrix, Pugh Matrix, Criteria
Based Selection Matrix, House Of Quality (HOQ)
N/3 Voting Technique
Genera te the list of
solut ion = 50

Com bining a ll sim ilar

solut ions t o bring it
dow n = 30

Allow m embers to
choose 10 solut ion from
the list

Allow m embers to
choose 3 solut ion from
the list

Ta lly vot es f or each

m em ber
Nominal Grouping Technique (NGT)
Effort Benefit Matrix
Cost Time Matrix
Cost Matrix Cost Scale
Solution 1 Solution 2 Solution 3 0 - 50000 1
Member 1 2 3 1 Up to 100000 2
Member 2 4 3 5 Up to 150000 3
Member 3 4 2 1 Up to 200000 4
200000+ 5
Time Matrix
Solution 1 Solution 2 Solution 3 Time Scale
Member 1 3 2 1 0 - 15 Days 1
Member 2 4 3 2 Up to 30 Days 2
Member 3 1 3 1 Up to 45 Days 3
Up to 60 Days 4
Cost Time Matrix > 60 Days 5
Member 1 5 5 2
Member 2 8 6 7
Member 3 5 5 2

Total Score 18 16 11
 Vital Xs

Deployment Matrix
Validated Root Cause 5
Validated Root Cause 4
Validated Root Cause 3
Validated Root Cause 2
Validated Root Cause 1
Rating ( 1 to 10)
1 Lowest
10 Maximum

0
Action Plan 1

0
Action Plan 2

0
Action Plan 3

0
Action Plan 4

0
Action Plan 5

0
Action Plan 6

0
Action Plan 7
Quality Function

0
Action Plan 8

0
Action Plan 9
Quality Function Deployment

0
0 Action Plan 10

Action Plan 11
0

Action Plan 12
0

Action Plan 13
Deployment

Action Plan 14
0

Action Plan 15
0
0
0
0
0

Completeness Matrix
 Failure Modes and Effects Analysis

Historical Current Control

Evidence / Mechanism / RPN
Items Failure Mode Effect on EDR Severity Occurrence Detection RMS RTP Responsibility Deadline
Possibility of Detection Level in the (S*O*D)
Occurrence system

On Scale of 1-10 On Scale of 1-10 On Scale of 1-10

Action Plan - Root Cause 1 Failure Reason 1 1 is less severe 1 is less frequent 1 is easily detectable Choose from
10 is fatal 10 is very frequent 10 is not detectable

Failure Reason 2 Accept

Failure Reason 3 Avoid
Failure Reason 4 Reduce
Action Plan - Root Cause 2 Failure Reason 1 Transfer
 Hypothesis Tests – Validation &
Comparison – Before & After
Variance / Standard
Mean Based
Deviation Based

1 Variance Test
Target Valiation 1 Sample T Test Look at Chi Square P
Value

Comparing Before & 2 Variance Test

Paired T Test
After Look at Bonett’s P value
 Target Validation
Week 1 Week 2 Week 3 Week 4 Boxplot of Week 1
172 267 366 485 (with Ho and 95% t-confidence interval for the mean)

240 261 448 549

178 248 390 519
218 280 311 534
132 252 335 400
105 232 294 528
174 253 415 393
140 227 278 511 _
X
158 200 438 427 Ho

142 236 437 506

104 250 272 408
100 150 200 250 300 350 400
217 258 280 412 Week 1
102 200 365 424
179 194 299 463
231 296 382 429
128 217 361 504
219 183 303 424
191 258 331 437
120 198 431 444
 Boxplot of Week 2
(with Ho and 95% t-confidence interval for the mean)

_
X
Ho

200 250 300 350 400

Week 2

Boxplot of Week 3
(with Ho and 95% t-confidence interval for the mean)

_
X
Ho

250 300 350 400 450

Week 3

Boxplot of Week 4
(with Ho and 95% t-confidence interval for the mean)

_
X
Ho

400 420 440 460 480 500 520 540 560

Week 4
 Comparing Before & After
Boxplot of Week 1, Week 4
600

500

400
Data

300

200

100

Week 1 Week 4