Lean Six Sigm Program Nam

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DefineMeasure Analyze Improve Control

LEAN SIX SIGMA

Define Phase Road Map
Define Measure Analyze Improve

Define

Control

Activities
• Team

Tools
• Project

election and scoping • Review Project Charter • Validate High-Level Value Stream Map and Scope • Validate Voice of the Customer and Voice of the Business • Validate Problem Statement and Goals • Validate Financial Benefits • Create Communication Plan • Select and Launch Team • Develop Project Schedule • Complete Define Gate

Charter • Voice of the Customer and Kano Analysis • SIPOC Map • Project Valuation/ROIC Analysis Tools • RACI and Quad Charts • Stakeholder Analysis • Communication Plan • Effective Meeting Tools • Inquiry and Advocacy Skills • SWOT Analysis • Time Lines, Milestones, and Gantt Charting • Pareto Analysis
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Measure Phase Road Map
Define Measure Analyze Improve

Measure

Control

Activities
• Identify Key Input, Process and Output Metrics • • • • • •

Tools

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High/Low level process Maps Value Stream Map Operational Definitions • Develop Operational Definitions Data Collection Plan • Develop Data Collection Plan Statistical Sampling • Validate Measurement System Measurement System Analysis (MSA), Gage R&R • Collect Baseline Data • Constraint Identification • Determine Process Performance/Capability • Setup Reduction • Validate Business Opportunity • Generic Pull • Value Stream Map for deeper understanding & • Kaizen • TPM focus • Control Charts • Quick Wins (Control Plans) • Process Capability, Cp & Cpk • Measure Gate Review
3

Analyze Phase Road Map
Define Measure Analyze Improve

Analyze

Control

Activities
• Identify • Reduce • Confirm

Tools
• Process

Potential Root Causes List of Potential Root Causes Root Cause to Output Relationship Impact of Root Causes on Key Root Causes Analyze Gate

Constraint ID and Takt Time

Analysis
• Cause • FMEA • Hypothesis • Simple • ANOVA • Components • Conquering

& Effect Analysis Tests/Conf. Intervals

• Estimate

Outputs
• Prioritize • Complete

& Multiple Regression of Variation

Product and Process

Complexity
• Queuing

Theory

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Improve Phase Road Map
Define Measure Analyze Improve

Improve

Control

Activities
• Develop

Tools
Potential Solutions Select, and Optimize Best
• Replenishment • Stocking • Process • Process

Pull/Kanban

• Evaluate,

Strategy

Solutions
• Develop • Develop • Confirm • Develop

Flow Improvement Balancing Batch Sizing

‘To-Be’ Value Stream Map(s) and Implement Pilot Solution Attainment of Project Goals Full Scale Implementation Plan Improve Gate

• Analytical • Total

Productive Maintenance of Experiments (DOE) Selection Matrix

• Design

• Complete

• Solution • Piloting

and Simulation

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Control Phase Road Map
Define Measure Analyze Improve

Control

Control

Activities
• Implement • Develop

Tools
Mistake Proofing
• Mistake-Proofing/

SOP’s, Training Plan & Process

Zero Defects
• Standard

Controls
• Implement • Identify

Operating Procedures

Solution and Ongoing Process Measurements Project Replication Opportunities Control Gate Project to Process Owner

(SOP’s)
• Process • Visual

Control Plans Process Controls

Process Control Tools

• Statistical

• Complete • Transition

(SPC)
• Solution • Project • Team

Replication

Transition Model

Feedback Session

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This Training Manual and all materials, procedures and systems herein contained or depicted (the "Manual"), are the sole and exclusive property of Bonacorsi Consulting, L.L.C. The contents hereof contain proprietary trade secrets that are the private and confidential property of Bonacorsi Consulting. Unauthorized use, disclosure, or reproduction of any kind of any material contained in this Manual is expressly prohibited. The contents hereof are to be returned immediately upon termination of any relationship or agreement giving user authorization to possess or use such information or materials. Any unauthorized or illegal use shall subject the user to all remedies, both legal and equitable, available to Bonacorsi Consulting. This Manual may be altered, amended or supplemented by Bonacorsi Consulting from time to time. In the event of any inconsistency or conflict between a provision in this Manual and any federal, provincial, state or local statute, regulation, order or other law, such law will supersede the conflicting or inconsistent provision(s) of this Manual in all properties subject to that Steven Bonacorsi is a Senior Master law.

Black Belt instructor and coach. © 2006 by Bonacorsi Consulting, L.L.C. Steven Bonacorsi has trained All Rights Reserved. hundreds of Master Black Belts, Black Belts, Green Belts, and Project Sponsors and Executive Leaders in Lean Six Sigma DMAIC and Design for Lean Six Sigma process improvement methodologies.
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