You are on page 1of 13

# SQC UNIT BANGALORE, GREEN BELT PROGRAM

## GENERATING SOLUTION IDEAS

– Review what you know about the process and the
verified cause.
– Brainstorm solution ideas; use creativity techniques.
– Combine ideas into solutions.

243
SQC UNIT BANGALORE, GREEN BELT PROGRAM

## EVALUATING SOLUTION IDEAS

• Four ways to evaluate the potential
solutions are:
– Do paper-and-pen analysis (score each option
against criteria).
– Model or simulate the solutions.
– Do trial implementations.
– Check against common sense.

## • We’ll look at how to develop criteria next.

244
SQC UNIT BANGALORE, GREEN BELT PROGRAM

## A PATH TO BETTER SOLUTIONS

• In order to get better solutions, we will follow these steps:
– Generate Criteria
– Weight Criteria
– Evaluate Ideas
• The tool we will use for this is the Solution Prioritization Matrix.
Criteria and Weights
Easy Quick Tech Hi Impact Customers
Solution SUM
0.2 1.25 0.3 1.65 0.6
A 3.0 10 2.4 19.8 8.4 43.6

## D 1.2 7.5 2.7 19.8 5.4 36.6

245
SQC UNIT BANGALORE, GREEN BELT PROGRAM

## REDUCING OR ELIMINATING RISK

– By anticipating potential problems, you can often take
countermeasures to reduce or eliminate the risks.
– A common tool for this analysis is Failure Modes and
Effects Analysis (FMEA).

246
SQC UNIT BANGALORE, GREEN BELT PROGRAM

WHY PILOT?

## – Improve the solution

– Understand risks

## – Validate expected results

– Smooth implementation

## – Identify previously unknown performance

problems

247
SQC UNIT BANGALORE, GREEN BELT PROGRAM

WHEN TO PILOT
Pilot when:
– You need to confirm the expected results and
practicality of the solution.

## – The scope of the change is large, and reversing the

change would be difficult.

## – Changes would have far-reaching, unforeseen

consequences.
248
SQC UNIT BANGALORE, GREEN BELT PROGRAM

## STEPS OF A PILOT PROGRAM

1. Select steering committees
2. Brief participants
3. Plan Pilot
4. Inform associates
5. Train employees
6. Conduct pilot
7. Evaluate results
8. Increase scope
249
SQC UNIT BANGALORE, GREEN BELT PROGRAM

## CRITICAL ISSUES IN PLANNING A PILOT

– Where to pilot? What line or machine?
– Use final or interim production equipment?
– How do we ensure that the full range of process
conditions is tested during the pilot?
– How many to make to statistically be sure that the
process is capable to produce the required quality?
– What needs to be measured? When? Where?
– How do we ensure that pilot products are contained?
– How to minimize disruptive impacts on the business
while ensuring the validity of the pilot?
– How to evaluate the results of the pilot?
250
SQC UNIT BANGALORE, GREEN BELT PROGRAM

## EVALUATE THE PILOT

– Compare results against the original definition
of a defect and against CTQs.

capability.

## – Analyze causal relationships and process

conditions.

251
SQC UNIT BANGALORE, GREEN BELT PROGRAM

ELEMENTS OF A PLAN
Tasks & Timeline Budget & Resources Stakeholders
PERSON Communication
Step Aug. Sept. Oct. Nov. Dec. Jan. Feb. Expenses or GROUP & Participation
xxxxx 00.00 Finance
xxxxx 00.00
xxxxx 00.00 Sales
Staff time
IS
Ted 5 hrs

## Step Pot. Pot. Counter-

PLAN ACTUALS
Failure Cause measures

252
SQC UNIT BANGALORE, GREEN BELT PROGRAM

## PLANNING GRID FEATURES

Outcome of each Person(s)
Steps listed step clearly responsible
sequentially identified identified

Whom
Step Respon- Due Budget/ Other
Step Deliverable to
Number sibility Date Cost Topics
Involve

Calvin, Dept.
Develop new wiring Wiring Plan Max, 6/12 N/A
staff,
1 schematic Sheryl Maria
Conduct Changes Machine Dept.
2 Changes
Maria 6/12
staff
N/A

3 Maria 6/16 N/A

## Update Documentation Other

Calvin 6/8 N/A
4 documentation dept
supv

Timing and
other factors
tracked

253
SQC UNIT BANGALORE, GREEN BELT PROGRAM

## THE PEOPLE SIDE

– Too often we spend all our time on the “technical” side of a
change—what has to happen by when, etc.
– We ignore the people side of the change—how to help those
who will have to change their ways of doing things in order
to realize the new change.
– There are three elements of the people side:
• Communication: the exchange of information both from you to
others and from others to you.
• Participation: involving people in the planning and execution of a
change so they can develop shared ownership and commitment.
• Education: providing people with what they will need to know
before they successfully implement the desired changes.
254
SQC UNIT BANGALORE, GREEN BELT PROGRAM

255