Lean Six Sigma DMAIC Workshop Green Belt Part 6 4/20/2017 Green Belt Training

Control Control 4/20/2017 Green Belt Training

Develop Control strategy Control Process Flow Develop Control strategy Develop control plan Update SOP’s and training plans 4/20/2017 Green Belt Training

Prevention vs detection Visual Factory Control Plan Reaction Plan Key Concepts Prevention vs detection Visual Factory Control Plan Reaction Plan 4/20/2017 Green Belt Training

Sustaining the gains is key! Control Phase Control is a means of sustaining improvements by eliminating the opportunity for defects to occur, or monitoring the process using a feedback system Sustaining the gains is key! We move from detection of defects to prevention of defects 4/20/2017 Green Belt Training

The avoidance of an error before it occurs Error Proofing The avoidance of an error before it occurs Error-proofed processes are designed to require extensive operator training while allowing the operation to be performed the correct way EVERY time. Automation Fixtures Jigs 4/20/2017 Green Belt Training

Visual Factory Visual Displays Communicate important information, but do not what people or machines do Visual Controls Communicate information and/or build controls into the process so that activities are performed according to standards 4/20/2017 Green Belt Training

Control Charts Control Charts 4/20/2017 Green Belt Training

Variation exists in all processes Variation means that a process does not produce exactly the same result every time the product or service is delivered Variation exists in all processes Measuring and understanding variation in our business processes helps identify specifically what the current level of performance is and what needs to change in order to reduce the variability and therefore reduce the defects delivered to customers 4/20/2017 Green Belt Training

Market What Causes Variation? Suppliers Process Inputs Critical Customer Requirement Market Suppliers Process Inputs Business Processes Process Outputs Defects Root cause analysis of variation leads to permanent defect reduction Variation in the output of processes causes defects 4/20/2017 Green Belt Training

Help us to detect, diagnose, and correct Control Charts - Basics Control Charts Have the ability to indicate the presence of special causes that upset our processes Help us to detect, diagnose, and correct production problems in a timely fashion Provide an easy to understand visual indicator of process performance 4/20/2017 Green Belt Training

Steps to building an appropriate control chart Control Charts - Basics Steps to building an appropriate control chart 1. Determine the type of data 2. Collect data consistently 3. Select the appropriate control chart 4. Build the control chart 5. Analyze process performance 6. Take corrective action 4/20/2017 Green Belt Training

Variation within a stable pattern is inevitable Common Cause Variation There are always inherent chance causes responsible for natural variation in all processes due to “normal” variation in materials, environments, methods, etc. (common cause) Variation within a stable pattern is inevitable 4/20/2017 Green Belt Training

Special Cause Variation Once we have an indication of a shift outside a stable pattern of variation, we must discover the reason for the shift (special cause) We want to remove the influence of a special cause if it is adversely affecting product-process quality If the special cause influence is improving product-process quality (e.g., 6 Sigma projects), we want to permanently capture its effect 4/20/2017 Green Belt Training

Out of Control Variation Eliminate Special Causes Commuting Time (mins) In Control Variation Out of Control Variation Commuting Time (mins) Days Time 4/20/2017 Green Belt Training

It is critical to understand that: Issues on Control Charts It is critical to understand that: Control charts do not tell us whether or not we are meeting tolerance specifications consistently They neither explicitly identify nor remove special causes Control charts are statistical based devices for addressing process stability We need to develop meaningful process logs to account for and document physical characteristics, action items, and results obtained 4/20/2017 Green Belt Training

Charting Variation – Control Charts Commuting Time (mins) Days 4/20/2017 Green Belt Training

Improves overall quality by reducing chances of deviation Benefits of a Well-Defined Control Plan Improves overall quality by reducing chances of deviation Reduces defects by keeping processes centered Aid in timely troubleshooting of the process Serve as a communication tool for changes in CCR‘s Sustain improvements 4/20/2017 Green Belt Training

Characteristic/Parameter CCR Specification/Requirement Control Plan Contents Characteristic/Parameter CCR Specification/Requirement Measurement Method Sample Size Frequency Who measures Where recorded Decision Rule/Corrective Action 4/20/2017 Green Belt Training

Actions to be taken when an out of control condition occurs Reaction Plan Actions to be taken when an out of control condition occurs When do we react? Who needs to be involved? What other information do we need to have? 4/20/2017 Green Belt Training

Procedures and Standards Procedures and standards are the details behind the activities documented on the business process map They serve as a vehicle for every employee -from senior executives to hourly workers -to gain an understanding of the improvement Procedures are both a training aid and a means to ensure successful implementation 4/20/2017 Green Belt Training

They should describe how to prevent product and service variation Procedures and Standards Contents They should be at such a level that the job can be performed well by employees who are not fully trained They should be specific. Tell precisely what actions to take and when and where to take them. Make it clear where people‘s responsibilities lie They should describe how to prevent product and service variation They must be able to be followed. No contradictory or unrealistic instructions. Priorities must be considered. Focus on the root causes Formats – Procedures – Checklists – Flowcharts – Metrics 4/20/2017 Green Belt Training

Channels: There are numerous communication channels such as: Communication Planning Research has shown that one of the most significant variables in successful implementation is the quality of communications supporting a change. Teams must be very careful to develop the right communications for the right people and deliver them at the right time Channels: There are numerous communication channels such as: One-on-one meetings Electronic mail Posters Bulletin boards Small discussion groups or workshops Videos Teleconferencing or video teleconferencing Memorandums or personalized letters Voice mail 4/20/2017 Green Belt Training

Do your research and preparation: Understand audience Presentation Checklist Do your research and preparation: Understand audience Include stakeholders Anticipate questions Presentation Opening: Set the expectations Share the burning platform Establish a sense of urgency 4/20/2017 Green Belt Training

Present “As Is” and “To Be” Use facts and data Presentation Checklist Deliver Body: Present “As Is” and “To Be” Use facts and data Show how stages of DMAIC tools were used Sell Your Solution: Be Specific Provide Examples to prove point Link Benefit/results to actions 4/20/2017 Green Belt Training

Present resource requirements Ask for approval Follow-up: Presentation Checklist Closing: Make recommendations Include How-By Present resource requirements Ask for approval Follow-up: Post presentation debrief Publish meeting minutes Thank participants 4/20/2017 Green Belt Training

Appendix Appendix 4/20/2017 Green Belt Training

How to Apply this Tool in my Work Statistical Tools Summary Tool What Type of Data When to Use How to Apply this Tool in my Work Histogram Visual display of one variable showing data center, spread, shape and outliers Continuous or discrete 1. Summarize large amounts of data 2. To get a “feel for the data‟ 3. To compare actual description to customer specs Multivari Charts Bar chart comparison of subgroups on one variable. To visually compare sub-groups by individual data points and the mean. In MINITAB 12 only. To identify major source of variation. Box Plots Visual display of the summary of Y data grouped by category of X Y=continuous X=discrete or categorical Summary display to visualize differences in data center, spread and shape across categories. Run Charts Plots observation in time sequence Y=continuous or To view process performance over time for trends, shifts or cycles. Control Charts Plots observations in time sequence against a mean and control limits To monitor the process in order to control and improve process performance over time for trends, shifts or cycles. To identify special causes. Scatter Diagram (Plot) Plots a response Y versus a predictor X X=continuous To understand the possible relationships between two variables. To identify possible root causes which are related to Y. Do not use with special causes. 4/20/2017 Green Belt Training

How to Apply this Tool in my Work Statistical Tools Summary Tool What Type of Data When to Use How to Apply this Tool in my Work Behaviorally Anchored Scales A response scale on which specific points are named or described to clarify the differences between points. Discrete / Categorical: Nominal(name) Ordinal(order) Continuous: Interval To translate subjective or qualitative issues into data (discrete or continuous). To reduce variation in the response measured. t-Test Determine if there is a difference between two groups. Y=continuous X=discrete or categorical Test if sample average = specified value Test if 2 sample means are equal Paired t: to reduce variation when comparing two sample averages Analysis Analysis of Variance Determine if there is a difference among many groups. (2 or more Xs) Determine of there is a statistically significant difference among the groups. Discrete Data: Chi Square Determine Determine if there is a difference for observed frequencies of 2 discrete variables. Y=discrete or categorical X=discrete or categorical Determine if there are relationships between two discrete variables. 4/20/2017 Green Belt Training

How to Apply this Tool in my Work Statistical Tools Summary Tool What Type of Data When to Use How to Apply this Tool in my Work Regression(Linear &Multiple) Summarizes, describes, predicts and quantifies relationships. Y=continuous X=continuous or discrete Determine if there is evidence of a relationship between Xs and Ys. Model data to develop a mathematical equation to quantify the relationship. Identify root causes. Make predictions using the model. Logistic Regression Y=discrete X=continuous or discrete Design of Experiments(DOE) Systematic and efficient proactive approach to testing relationships. Y=continuous or discrete X=continuous or discrete To establish cause and effect relationship between Ys and Xs. To identify “vital few” Xs. 4/20/2017 Green Belt Training

Websites: www.isixsigma.com www.asq.org/sixsigma/ www.minitab.com/ Control Websites: www.isixsigma.com www.asq.org/sixsigma/ www.minitab.com/ 4/20/2017 Green Belt Training