For Each Verified Cause

Do we already know the best operating

condition that would remove/reduce the
effect of this cause?

Yes
No

Control Phase Improve Phase

Implement controls • Brainstorm and evaluate
to assure the best counteractions.
operating condition • Select the one that offers
is always followed. greatest potential.
–SOP’s • Test its effectiveness through
–Visual Controls DOE or other means.
–Error-proofing

T E
NO Often it is useful to brainstorm counteractions even when “best practices” are
thought to be known. The team could generate ideas that are better yet!

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 Methods for Determining Solutions
1. Brainstorming
– Brainstorm how to counteract verified cause.
2. Evaluation Matrix
– Evaluate and select best ideas for counteracting causes.
3. Design of Experiments (DOE)
– Determine best operating conditions.
– Verify the solutions (counteractions) selected through
brainstorming and the evaluation matrix.
– Verify the impact of causes.
4. Regression Analysis
– Determine factors to include in a DOE.
– When comprehensive existing data base is available, determine
best operating conditions through multiple regression.
E All of these methods apply to both transactional and
T
NO operational processes.

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 Useful Counteractions
Good counteractions are
• Well defined &
• Actionable

Examples of well defined,

actionable counteractions:

• Create quarterly goals for the

Six Sigma Implementation Plan

• Add cavity pressure transducer

to cut off injection pressure at
set point.

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 Less Useful Counteractions
Examples of less useful counteractions (too vague, not actionable):

• Improve communication
• Develop process focus
• Improve injection molding quality

• Using such counteractions only leads to confusion, since people

don’t understand the specific actions to take.

• When these kinds of counteractions arise in brainstorming, ask,

“what specific actions do we need to take to accomplish this item?”

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 Prototype Process –
Brainstorm Counteractions (Cont.)
Verified Cause of Long Processing Time:

Data entry errors cause extra rework time.

Team’s Ideas for Counteracting this Cause:

• Fax from master contact list.
• Send supplier e-mail version of the PO file.
• Auto-fax: Modify Access Database to fax and e-mail
confirm
• Request call return from supplier

Johnson Controls, Inc. © 02.20.02 5 W4ReviewofImprovePhase.ppt

 Prototype Process –
Evaluating Counteractions

Effectiveness

Ease to Implement

Cost
Counteractions

Fax from Master Contact List   

Send Supplier E-Mail version of the PO file   
Auto-fax: Modify Access Database to fax and e-mail   
confirm.
Request Call Return from Supplier   

Legend:  Very effective, easy to implement, low cost

 Moderately effective, moderately east to implement, moderate cost
 Not very effective, hard to implement, high cost

io n Which idea should the team select?

u est
Q
Johnson Controls, Inc. © 02.20.02 6 W4ReviewofImprovePhase.ppt