Professional Documents
Culture Documents
6 Analyze CTQ Identify Variation Sources Do we know the major family of variation?
Page 3
Breakthrough Strategy
Mean, target, Spec Limits, functional limits, Communication with customers, Strat Plan,
Graphical presentation of requirements
required capability Design specifications
Baseline and target m, s, Cp, Cpk, Pp, Ppk Picture of "is" and "ought" Minitab
Process Map and capabilities of each input Process Map, FMEA, Cause and Effect
Inputs, noise variables
variables Matrix, Multivari chart
Direction of effect and sensitivity of selected Main Effects Plot, ANOVA, e (SSe/SSt),
Graphical and tabular form
CTP's with respect to m, s Autocorrelation, Regression
Page 4
Breakthrough Strategy
Data Location
Continuous and discrete data, Spec Limits
Simulator, QA/QC, Manufacturing
for short term,
Page 5
Six Sigma Project Template
Project Name
Group Name Black Belt Name
Project Objective/Desired State State the Project Objective/Desired State and make sure it links back to the Problem Statement
Description:
Other Information Include any other information related to the Project as necessary
Project Managers:
Date:
Step No. Activity Responsible Volume No. Total hrs NVA NVA hrs/
position per week individuals per week (Y/N?) week
(1) (2) (3) (4) (5) (6) (7) (8)
1 2 56 3 4 4 6 7
4 67 50 79 6 6 7
6 78 97 154 8 6 7
8 89 144 229 10 6 7
10 100 191 304 12 6 7
12 111 238 379 14 6 7
14 122 285 454 16 6 7
16 133 332 529 18 6 7
18 144 379 604 20 6 7
20 155 426 679 22 6 7
22 166 473 754 24 6 7
24 177 520 829 26 6 7
26 188 567 904 28 6 7
28 199 614 979 30 6 7
30 210 661 1054 32 6 7
32 221 708 1129 34 6 7
34 232 755 1204 36 6 7
36 243 802 1279 38 6 7
38 254 849 1354 40 6 7
Sum=
808 763 63 123 345 43 232
Mileu Méthode
Le chronomètrage
n'est pas à jour
5 S non réspecté
Contrôle aléatoire des
piéces coupées
Machine
Méthode Matière
Manque de
MPdfwxdsqzaz
oire des
es
Consommation énorme de
la matière première
Effectif faible
Main d'oeuvre
Post de travail non ergonomique 5 S
non réspecté Trop de déplacement
des opérateurs Non respect des des
modes opératoires Le
chronomètrage Contrôle aléatoire
des piéces coupées n'est pas à jour
Contrôle aléatoire des piéces
coupées Manque de MP Trop de
variété des modèles Consommation
énorme de la matière première
Usure de la lame de coupe et de la
bande Chengement des paramètres
de coupe Défauts de coupe Manque
Causes
de formation continue Effectif faible
Manque de travail d'équipe
5 S non réspecté
- Augumentation des
interruptions
- Baisse d'efficience
Brainstorm Potential Root Causes
Problem
Statement:
Rank Potential Root Cause Supporting Data & Analysis?* Source? Who? When?
2. Solution a)
b)
c)
3. Solution a)
b)
Solution Evaluation Form
List Root Cause(s) List Solutions % Effect Estimated Cost Complexity Estimated Benefit Risk* Priority Validation?
Root Cause 1 Solutions 1
% of cost time or savings High Order Need
effect of effort to due to Medium of potential to
solution solution implement solution or solution verify
will have implementation short term? or Low implmentation effectiveness
on the long term? improvement 1st, 2nd, 3rd of solution
root cause in customer
satisfaction
Root Cause 2
Name of X or Y Clear definition of Visual Data tags are Manual? State What Location How The number
parameter attribute or the measurement inspection defined for the Spreadsheet? who has measure is for often of data
or condition discrete defined in such a or automated measure. Such Computer based? the being data the points
to be data, way as to achieve test? as: time, date, etc. responsibility? collected collection data collected
measured product or repeatable results Test instruments location, tester, is per sample
process from multiple are defined. line, customer, collected
data observers buyer, operator,
Procedures for etc.
data collection
are defined.
Measure Relationships
Responses or Outputs (Ys) Factors (Xs)
Dependent Variable USL LSL Target Independent Variable(s) USL LSL Target
Root Cause Analysis Timeline
Project Name: Start Date: 6/10/2002
Use lines and or color bars to indicate start and stop dates for each activity
Phase: Activity Start Date End Date Assigned to: 6/10/2002 6/11/2002 6/12/2002 6/13/2002 6/14/2002 6/15/2002 6/16/2002 6/17/2002
1. Define and
Contain the
Problem
2. Measure the
Problem
3. Perform
Root Cause
Analysis
4. Plan and
Implement
Improvement
5. Assess
Effectiveness of
Improvement
6. Standardize
and Control
7. Realize and
Reflect
Root Cause Analysis Timeline
Project Name:
Phase: Activity Start Date End Date Assigned to: 6/18/2002 6/19/2002 6/20/2002 6/21/2002 6/22/2002 6/23/2002 6/24/2002 6/25/2002
1. Define and
Contain the
Problem
2. Measure the
Problem
3. Perform
Root Cause
Analysis
4. Plan and
Implement
Improvement
5. Assess
Effectiveness of
Improvement
6. Standardize
and Control
7. Realize and
Reflect
Root Cause Analysis Timeline
Project Name:
Phase: Activity Start Date End Date Assigned to: 6/26/2002 6/27/2002 6/28/2002 6/29/2002 6/30/2002 7/1/2002 7/2/2002 7/3/2002 7/4/2002
1. Define and
Contain the
Problem
2. Measure the
Problem
3. Perform
Root Cause
Analysis
4. Plan and
Implement
Improvement
5. Assess
Effectiveness of
Improvement
6. Standardize
and Control
7. Realize and
Reflect
Root Cause Analysis Timeline
Project Name:
Phase: Activity Start Date End Date Assigned to: 7/5/2002 7/6/2002 7/7/2002 7/8/2002 7/9/2002 7/10/2002
1. Define and
Contain the
Problem
2. Measure the
Problem
3. Perform
Root Cause
Analysis
4. Plan and
Implement
Improvement
5. Assess
Effectiveness of
Improvement
6. Standardize
and Control
7. Realize and
Reflect
DOE 2^2 template
ANOVA
REGRESSION MODEL
Page 26
DOE 2^2 template
Intercept 27.50
A coefficient 4.1667
B coefficient -2.5
AB coefficient 0
PREDICTION EQUATION
A 1
B 1
Y-hat 29.17
RESIDUALS
Actual Pred Residual rank Perc Z
1 -1 -1 28 25.83 2.167 1 2.5 -1.96 3.000
2 -1 -1 25 25.83 -0.833 16 77.5 0.755
3 -1 -1 27 25.83 1.167 5 22.5 -0.755 2.000
4 -1 -1 0 0 0.000 7 32.5 -0.454
5 -1 -1 0 0 0.000 7 32.5 -0.454
1.000
1 1 -1 36 34.17 1.833 3 12.5 -1.15
2 1 -1 32 34.17 -2.167 18 87.5 1.15
3 1 -1 32 34.17 -2.167 18 87.5 1.15 0.000
0 5 10 15 20 25
4 1 -1 0 0 0.000 7 32.5 -0.454
5 1 -1 0 0 0.000 7 32.5 -0.454 -1.000
1 -1 1 18 20.83 -2.833 20 97.5 1.96
2 -1 1 19 20.83 -1.833 17 82.5 0.935 -2.000
3 -1 1 23 20.83 2.167 1 2.5 -1.96
4 -1 1 0 0 0.000 7 32.5 -0.454 -3.000
5 -1 1 0 0 0.000 7 32.5 -0.454
1 1 1 31 29.17 1.833 3 12.5 -1.15
-4.000
2 1 1 30 29.17 0.833 6 27.5 -0.598
3 1 1 29 29.17 -0.167 15 72.5 0.598
4 1 1 0 0 0.000 7 32.5 -0.454
5 1 1 0 0 0.000 7 32.5 -0.454
Page 27
DOE 2^2 template
EFFECTS PLOT
Page 28
DOE 2^2 template
B- B+
A- 26.7 20
A+ 33.3 30
Page 29
DOE 2^3 template
Page 30
AB Interaction AC Interaction BC Interaction
2.50 2.50 2.50
2.00 2.00 2.00
1.50 1.50
DOE 2^3 template
1.50
1.00 1.00 1.00
0.50 B- 0.50 0.50
C- C-
0.00 0.00 0.00
B+ C+ C+
A- A+ A- A+ B- B+
REGRESSION MODEL
Intercept 2.00
A coefficient 0
B coefficient 0
C coefficient 0
AB coefficient 0
AC coefficient 0
BC coefficient 0
ABC coefficient 0
PREDICTION EQUATION
A 1
B 1
C 1
Y-hat 2.00
Page 31
DOE 2^3 template
Page 32
DOE 2^3 template
ANOVA
B- B+
A- 2.00 2.00
A+ 2.00 2.00
C- C+
A- 2.00 2.00
A+ 2.00 2.00
C- C+
B- 2.00 2.00
B+ 2.00 2.00
action
C-
C+
B+
Page 33
action
C-
C+
B+
Page 34
Parts per Million Calculator
This is a simple sigma level calculator
RTY= 0.99472
DPMO Calculator
This template calculates the DPMO using the number of defects.
DPMO = 80
Calibration GR&R
Date Resoluton Bias Linearity Stability Notes
Date By %R&R P/T Disc Index
Baseline
In-Service
In-Service
In-Service
In-Service
In-Service
In-Service
In-Service
In-Service
External Client Management
Cost
Matrix
Metric
Target
1=Weak
Call Work
9=Strong,
Hold Time
Call Backs
IVR Usage
Compliance
Relationship
Call Blocked
3=Moderate,
Service Level
Risk Exposure
Calls Per Hour
Time in Queue
How Important
Productivity and
Call Transferred
POC Resolution
Call Duration and
0
Quality of Service
0
Staffing Levels
0
Call Volume
0
Call Routing
0
Training
0
Systems Problems
0
Information Sources:
0
Speed/Availability
Call Blocking
0
Availability of Other Depts
0
Exception Processing
0
Rework Reduction
0
Experience Level of Reps
0
Delivery of Info
0
Technology Limitations
0
0
How Important
Baseline
Metric
Target
Cause & Effect Matrix
Rating of
Importance to
Customer
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 0
11 0
12 0
13 0
14 0
15 0
16 0
17 0
18 0
19 0
20 0
0
Total
0
Page 46
Potential Failure Modes and
Effects Analysis (Information
Sheet)
PFMEA Number:
Process Name:
Process Responsibility:
Prepared By:
Affected Product(s):
Process or
Prepared by: Page ____ of ____
Product Name:
S O D R S O D R
Key Process Actions
Process Step Potential Failure Mode Potential Failure Effects E Potential Causes C Current Controls E P Resp. Actions Taken E C E P
Input Recommended
V C T N V C T N
What is the What is the Key In what ways does the Key What is the impact on the Key What causes the Key Input to What are the existing controls and What are the actions Whose What are the completed
cause or FM occur?
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
Page 48
FSeverity
Minor disruption to production line. Product may have to be sorted and a portion
High (less than 100%) scrapped. Vehicle operable, but at a reduced level of 7
performance. Customer dissatisfied.
Minor disruption to production line. A portion (less than 100%) may have to be
Moderate scrapped (no sorting). Vehicle / item operable, but some comfort / convenience 6
item(s) inoperable. Customers experience discomfort.
Minor disruption to production line. 100% of product may have to be reworked.
Low Vehicle / item operable, but some comfort / convenience item(s) operable at 5
reduced level of performance. Customer experiences some dissatisfaction.
Minor disruption to production line. The product may have to be sorted and a
Very Low portion (less than 100%) reworked. Fit / finish / squeak / rattle item does not 4
conform. Defect noticed by most customers.
Minor disruption to production line. A portion (less than 100%) of the product may
Minor have to be reworked on-line but out-of-station. Fit / finish / squeak / rattle item does 3
not conform. Defect noticed by average customers.
Minor disruption to production line. A portion (less than 100%) of the product may
Very Minor have to be reworked on-line but in-station. Fit / finish / squeak / rattle item does not 2
conform. Defect noticed by discriminating customers.
None No effect. 1
Page 49
FOccurance
Page 50
FDetection
Page 51
Control Plan
Date (Rev):
Specification/
Sub Process CTQ Specification Measurement Who Where Decision Rule/
Sub Process Requirement Sample Size Frequency SOP Reference
Step Characteristic Method Measures Recorded Corrective Action
KPOV KPIV USL LSL
Six Sigma Preventative Maintenance Plan
Process Name: Prepared by: Page: of
Customer Int/Ext Approved by: Document No:
Upper Lower
Customer Requirement Measurement %R&R or P/T Sample
Spec Target Spec Cp Cpk Date
(Output Variable) Technique Ratio Size
Limit Limit
Actions
Failure Mode and Effects Analysis
(Design FMEA) FMEA Number:
Page of
System/Component: Design Responsibility: Prepared by:
FMEA Date (Orig.) (Rev.)
Core Team:
Action Results
O D
Item / O D
S Potential Cause(s)/ c e R. Responsibility &
Process Potential Failure Potential Effect(s) of Current Design Current Design Recommended S c e R.
e Mechanism(s) of c t P. Target Completion
Mode Failure Controls Prevention Controls Detection Action(s) ActionsTaken e c t P.
v Failure u e N. Date
Function v u e N.
r c
r c
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
Z
Z-Value 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0.0 0.50000 0.49601 0.49202 0.48803 0.48405 0.48006 0.47608 0.47210 0.46812 0.46414
0.1 0.46017 0.45620 0.45224 0.44828 0.44433 0.44038 0.43644 0.43251 0.42858 0.42465
0.2 0.42074 0.41683 0.41294 0.40905 0.40517 0.40129 0.39743 0.39358 0.38974 0.38591
0.3 0.38209 0.37828 0.37448 0.37070 0.36693 0.36317 0.35942 0.35569 0.35197 0.34827
0.4 0.34458 0.34090 0.33724 0.33360 0.32997 0.32636 0.32276 0.31918 0.31561 0.31207
0.5 0.30854 0.30503 0.30153 0.29806 0.29460 0.29116 0.28774 0.28434 0.28096 0.27760
0.6 0.27425 0.27093 0.26763 0.26435 0.26109 0.25785 0.25463 0.25143 0.24825 0.24510
0.7 0.24196 0.23885 0.23576 0.23270 0.22965 0.22663 0.22363 0.22065 0.21770 0.21476
0.8 0.21186 0.20897 0.20611 0.20327 0.20045 0.19766 0.19489 0.19215 0.18943 0.18673
0.9 0.18406 0.18141 0.17879 0.17619 0.17361 0.17106 0.16853 0.16602 0.16354 0.16109
1.0 0.15866 0.15625 0.15386 0.15151 0.14917 0.14686 0.14457 0.14231 0.14007 0.13786
1.1 0.13567 0.13350 0.13136 0.12924 0.12714 0.12507 0.12302 0.12100 0.11900 0.11702
1.2 0.11507 0.11314 0.11123 0.10935 0.10749 0.10565 0.10383 0.10204 0.10027 0.09853
1.3 0.09680 0.09510 0.09342 0.09176 0.09012 0.08851 0.08691 0.08534 0.08379 0.08226
1.4 0.08076 0.07927 0.07780 0.07636 0.07493 0.07353 0.07215 0.07078 0.06944 0.06811
1.5 0.06681 0.06552 0.06426 0.06301 0.06178 0.06057 0.05938 0.05821 0.05705 0.05592
1.6 0.05480 0.05370 0.05262 0.05155 0.05050 0.04947 0.04846 0.04746 0.04648 0.04551
1.7 0.04457 0.04363 0.04272 0.04182 0.04093 0.04006 0.03920 0.03836 0.03754 0.03673
1.8 0.03593 0.03515 0.03438 0.03362 0.03288 0.03216 0.03144 0.03074 0.03005 0.02938
1.9 0.02872 0.02807 0.02743 0.02680 0.02619 0.02559 0.02500 0.02442 0.02385 0.02330
2.0 0.02275 0.02222 0.02169 0.02118 0.02068 0.02018 0.01970 0.01923 0.01876 0.01831
2.1 0.01786 0.01743 0.01700 0.01659 0.01618 0.01578 0.01539 0.01500 0.01463 0.01426
2.2 0.01390 0.01355 0.01321 0.01287 0.01255 0.01222 0.01191 0.01160 0.01130 0.01101
2.3 0.01072 0.01044 0.01017 0.00990 0.00964 0.00939 0.00914 0.00889 0.00866 0.00842
2.4 0.00820 0.00798 0.00776 0.00755 0.00734 0.00714 0.00695 0.00676 0.00657 0.00639
2.5 0.00621 0.00604 0.00587 0.00570 0.00554 0.00539 0.00523 0.00508 0.00494 0.00480
2.6 0.00466 0.00453 0.00440 0.00427 0.00415 0.00402 0.00391 0.00379 0.00368 0.00357
2.7 0.00347 0.00336 0.00326 0.00317 0.00307 0.00298 0.00289 0.00280 0.00272 0.00264
2.8 0.00256 0.00248 0.00240 0.00233 0.00226 0.00219 0.00212 0.00205 0.00199 0.00193
2.9 0.00187 0.00181 0.00175 0.00169 0.00164 0.00159 0.00154 0.00149 0.00144 0.00139
3.0 0.00135 0.00131 0.00126 0.00122 0.00118 0.00114 0.00111 0.00107 0.00104 0.00100
3.1 0.00097 0.00094 0.00090 0.00087 0.00084 0.00082 0.00079 0.00076 0.00074 0.00071
3.2 0.00069 0.00066 0.00064 0.00062 0.00060 0.00058 0.00056 0.00054 0.00052 0.00050
3.3 0.00048 0.00047 0.00045 0.00043 0.00042 0.00040 0.00039 0.00038 0.00036 0.00035
3.4 0.00034 0.00032 0.00031 0.00030 0.00029 0.00028 0.00027 0.00026 0.00025 0.00024
3.5 0.00023 0.00022 0.00022 0.00021 0.00020 0.00019 0.00019 0.00018 0.00017 0.00017
3.6 0.00016 0.00015 0.00015 0.00014 0.00014 0.00013 0.00013 0.00012 0.00012 0.00011
3.7 0.00011 0.00010 0.00010 0.00010 0.00009 0.00009 0.00008 0.00008 0.00008 0.00008
3.8 0.00007 0.00007 0.00007 0.00006 0.00006 0.00006 0.00006 0.00005 0.00005 0.00005
3.9 0.00005 0.00005 0.00004 0.00004 0.00004 0.00004 0.00004 0.00004 0.00003 0.00003
4.0 0.00003 0.00003 0.00003 0.00003 0.00003 0.00003 0.00002 0.00002 0.00002 0.00002