Practical Assessment Project Template Project title: <title of the project> Organization: <name of your organization> Project leader: <your name> Belt level: <Black or Green Belt> Revision date: <e.g. 28-09-2015> Practical Assessment Project Template Date: -

DMAIC Introduction for this template Objectives of this presentation: Certification by LSSA Project summary for your organization Guidelines: Methodology and logic understandable, for a Six Sigma trained external colleague Clear conclusions on each sheet Target for certification is max. 25 sheets (no limit for internal use) No back-up sheets Delete the (Italic) notes for the user, upon need Delete this slide before handing in.

DMAIC Process improvement roadmap DMAIC roadmap Define 1 Define and Scope project 2 Define defect and CTQs 3 Plan and document project Measure 4 Evaluate measurement system 5 Establish baseline 6 Set improvement goals Analyze 7 Map process and identify inputs 8 Isolate key inputs 9 Develop Y=f(X) function Improve 10 Determine optimum settings 11 Implement proposed improvement 12 Validate proposed improvement Control 13 Implement control strategy 14 Close out project

DEFINE 1 – Define and scope project Problem Description: What is wrong, how does it affect the customer, what is the pain for the organization? Is it a priority, so in line with top-down priorities? Add picture or drawing to explain (If ready, delete this textbox) Objectives: What do we want to achieve? Helicopter view description. (delete this textbox)

DEFINE 1 – Define and scope project Target: Describe the quantified, measurable result (not the solution!). What is the required timing? In Scope What are the boundaries of the process to analyze; what are you allowed to change? Out of Scope: What not . . . ? Deliverables: What evidence to put at the table to show that targets metrics are met? This is the key element in the agreement with the champion Hard Benefits: Summarize the calculation to shows that this is a ‘major cost saving or cost avoidance, in keuro/year. Upon need add a separate sheet Soft Benefits: Any nice additional benefits, like customer satisfaction, learning Six Sigma

DEFINE 2 - Define defects and CTQs Start from customer perspective ‘OK for customer’ Customer specification Internal specification This can be a vague description of the critical variable CTQ ext Variable: ……… Target: ………… Specifications: …… CTQ ext Describe the measurable variable and specifications as required by the customer. Variable: ……… Conditions: …… Target: ………… Describe the measurable variable and specifications as defined in own organisation. Can be different from the CTQext, but must have a known/proven relation with CTQext. CTQ int High level, describe until highest level measurable CTQ int. (the project target) Legend: solid line: proven relation dotted line: relation tbd. grey box: out of scope white box: potential CTQ, or group of CTQs

DEFINE 3 – Plan and document project Project Team Supplier: Champion: User: MBB: who provides resources driving for success will benefit from the results coach for methodology Project leader (Belt): Actively involved members in team meetings Name: Role: Responsibility:

DEFINE 3 – Plan and document project SIPOC is mandatory for process improvement For design improvement: visualize product problem area SIPOC Process Map Supplier: Inputs: Process: Outputs: Customers: ‘Process’ Controllable variables + specs Output variables Main noises Standard Operating Procedures If helpful show below detailed steps on the process Step 1 Step 2 Step 3 Step 4 Step 5

Self Assessment LSSA Assessor Feedback DEFINE Assessment Self Assessment LSSA Assessor Feedback   Missing Incorrect Correct N/A Define 1 Project addresses a clear problem or business opportunity (€20,000.- p/year). 2 Problem description has been clearly defined. 3 Goals have been clearly defined. Project objectives are measurable. 4 VOC and VOB have been defined clearly. Requirements have been understood. 5 Scope of the project has been clearly delineated. 6 Key stakeholders have been involved and informed. 7 Belt has shown to be able to manage the project adequately. 8 Project has been completed within time and budget.   Missing Incorrect Correct N/A Define 1 Project addresses a clear problem or business opportunity (€20,000.- p/year). 2 Problem description has been clearly defined. 3 Goals have been clearly defined. Project objectives are measurable. 4 VOC and VOB have been defined clearly. Requirements have been understood. 5 Scope of the project has been clearly delineated. 6 Key stakeholders have been involved and informed. 7 Belt has shown to be able to manage the project adequately. 8 Project has been completed within time and budget.

MEASURE 4 – Evaluate measurement system For Target internal CTQ’s Evaluate whether measurement error for the CTQ int, described in the target is good enough for this project. e.g. reference data, GR&R, bias, attribute agreement, etc. Measurement error CTQ int Conclusion:

MEASURE 5 – Establish baseline How is the situation on the CTQ’s in the beginning of the project? (measured with the known error) e.g. results of capability & performance study If historical measurement error is unknown, add a note. Visualize if possible, for instance in time. Conclusion:

MEASURE 6 – Set improvement goals Final Target Evaluate whether the original target(s) are realistic. If necessary describe the rational why the targets are being adjusted. Conclusion:

Self Assessment LSSA Assessor Feedback MEASURE Assessment Self Assessment LSSA Assessor Feedback   Missing Incorrect Correct N/A Measure 1 Relevant KPI's have been selected / CTQ-flowdown has been constructed. 2 High level process description has been made (e.g. SIPOC). 3 Data has been collected / selected properly. 4 The collected data has been proven to be representative for the project. 5 Quality of the data has been verified in an appropriate way (GR&R if applicable). 6 Historical data has been used to visualize performance over time (e.g. Time series). 7 Variation in the process has been considered (common cause or special cause). 8 Short term versus long term performance has been considered. 9 Performance against requirements has been checked (Ppk if applicable).   Missing Incorrect Correct N/A Measure 1 Relevant KPI's have been selected / CTQ-flowdown has been constructed. 2 High level process description has been made (e.g. SIPOC). 3 Data has been collected / selected properly. 4 The collected data has been proven to be representative for the project. 5 Quality of the data has been verified in an appropriate way (GR&R if applicable). 6 Historical data has been used to visualize performance over time (e.g. Time series). 7 Variation in the process has been considered (common cause or special cause). 8 Short term versus long term performance has been considered. 9 Performance against requirements has been checked (Ppk if applicable).

ANALYZE 7 – Map process and identify inputs Process Map Input variable 1 Input variable 2 ............. Use this format for process improvement For design improvement use Boundary Diagram or Parameter Diagram , for the applicable function(s) (process step 1) Input variable 1 Input variable 2 ............. …. Input variable 1 Input variable 2 ............. …. Input variable 1 Input variable 2 ............. (process step x) Output variable 1 Output variable 2 Output variable 3 ............. These should be the CTQ’s Conclusion:

ANALYZE 7 - Map process and identify inputs Create this diagram to complete and categorize the list of inputs Ishikawa Diagram Measurement Machine Men Advice: use Xmind or Freemind Defect Methods Environment Materials Conclusion:

ANALYZE 8 – Isolate key inputs If a large number of inputs is identified, it is important to limit the analysis to a small set of important (key)inputs. Tools include: Cause & effect matrix, screening (DOE), FMEA Conclusion:

ANALYZE 9 – Develop Y=f(X) function Tools: Anova, Regression, DOE, simulation, etc Conclusion:

Self Assessment LSSA Assessor Feedback ANALYZE Assessment Self Assessment LSSA Assessor Feedback   Missing Incorrect Correct N/A Analyze 1 Process has been mapped in detail (e.g. Process Flow / VSM Current State). 2 Potential root causes have been identified properly. 3 Data has been collected and analyzed correctly. 4 Graphical and statistical techniques have been applied to investigate root causes. 5 Major root causes have been identified. 6 Conclusions have demonstrated strong evidence / statistically valid.   Missing Incorrect Correct N/A Analyze 1 Process has been mapped in detail (e.g. Process Flow / VSM Current State). 2 Potential root causes have been identified properly. 3 Data has been collected and analyzed correctly. 4 Graphical and statistical techniques have been applied to investigate root causes. 5 Major root causes have been identified. 6 Conclusions have demonstrated strong evidence / statistically valid.

IMPROVE 10 – Determine optimum settings DOE, simulation, etc Conclusion:

IMPROVE 11 – Implement proposed improvement Show a list of implemented improvements Conclusion:

IMPROVE 12 – Validate proposed improvement Show the verification run compared to baseline that the Define conditions will be met. Conclusion:

Self Assessment LSSA Assessor Feedback IMPROVE Assessment Self Assessment LSSA Assessor Feedback   Missing Incorrect Correct N/A Improve 1 Improved process meets the requirements of the VOC and VOB. 2 Risks have been assessed (e.g. pFMEA). 3 Resistance for change has been overcome / Risks have been mitigated. 4 Internal and external customers have accepted the new process. 5 Improvements have been proven to be successful. (Capability study if applicable).   Missing Incorrect Correct N/A Improve 1 Improved process meets the requirements of the VOC and VOB. 2 Risks have been assessed (e.g. pFMEA). 3 Resistance for change has been overcome / Risks have been mitigated. 4 Internal and external customers have accepted the new process. 5 Improvements have been proven to be successful. (Capability study if applicable).

CONTROL 13 – Implement control strategy Show the verification run compared to baseline that the Define conditions will be met. Conclusion:

CONTROL 13 – Implement control strategy Open actions …. Documentation Component drawings Manufacturing specifications Control plan Engineering reports FMEA .. Roles & responsibilities Actions and owners necessary to finish this project How is assured that all information is well documented for future success What are the key roles & responsibilities to assure continued success

CONTROL 14 – Close out project Conclusions …. Recommendations Lessons learned Relate this to the project objective, targets and deliverables For follow-up, next steps, or next projects For colleagues, others

CONTROL 14 – Close out project The realized benefits of this projects are: Summarize final total savings, average per year Champion: Date, Name & Signature - Controller: Date, Name & Signature - LSSA MBB: Date, Name & Signature -

Self Assessment LSSA Assessor Feedback CONTROL Assessment Self Assessment LSSA Assessor Feedback   Missing Incorrect Correct N/A Control 1 Evidence of 'In-Control situation' available and sufficient. 2 Measures have been put in place to monitor process performance. 3 Documentation has been updated (pFMEA, CP, SOP's). 4 Training has been performed for the new process. 5 Improvements have proven to be sustainable. 6 Project report has been completed. Lessons learned have been communicated. 7 Champion has been involved and signed the project. 8 Controller signed that project savings / benefits have been achieved.   Missing Incorrect Correct N/A Control 1 Evidence of 'In-Control situation' available and sufficient. 2 Measures have been put in place to monitor process performance. 3 Documentation has been updated (pFMEA, CP, SOP's). 4 Training has been performed for the new process. 5 Improvements have proven to be sustainable. 6 Project report has been completed. Lessons learned have been communicated. 7 Champion has been involved and signed the project. 8 Controller signed that project savings / benefits have been achieved.