1. Six Sigma at Boston Scientific Tuesday 12 September 2006 Steve Czarniak
BSC Six Sigma: ASQ Meeting – 12 September 2006

2. Session Objectives Describe the Boston Scientific Six Sigma Model
Describe the Boston Scientific Six Sigma Roadmaps
Identify which Minitab graphs to use to assess measurement system performance
BSC Six Sigma: ASQ Meeting – 12 September 2006

3. Six Sigma at BSC is...
BSC Six Sigma: ASQ Meeting – 12 September 2006

4. Improvement Challenges
Solution Known
Change in Performance
Operational Defect / Variation Reduction
Flow
Design
BSC Six Sigma: ASQ Meeting – 12 September 2006

5. BSC Six Sigma Problem Solving Roadmap
BSC Six Sigma: ASQ Meeting – 12 September 2006

6. BSC Six Sigma Operational Process Improvement Roadmap
Process Improvement Process
Define
Identify
Opportunity
Identify y’s
(Outputs)
Measure
y = f(x)
Key x’s
(Inputs)
Analyze
Optimize
x’s
Improve
Control
Yield
Time
BSC Six Sigma: ASQ Meeting – 12 September 2006

7. DMAIC Improvement Process
Define
Measure
Analyze
Improve
Control
Identify Opportunity
Define Project Goal
Define Process
Establish Boundaries
Determine Customer Requirements
Define Key Y Variables
Develop Measures (y’s)
Evaluate Measurement System
Determine Process Stability
Determine Process Capability
Determine the Improvement Approach
Identify Potential x’s
Analyze x’s
Identify Key x’s
Determine Stability & Capability of Key x’s
Establish Relationships between y’s & x’s
Establish Targets & Tolerances for Key x’s
Implement Mistake Proofing
Develop, Select & Verify Process Improvements
Control Key x’s
Validate Process
Verify Long Term Capability
Monitor y’s
Finalize the Control System
Finalize Project Charter
BSC Six Sigma: ASQ Meeting – 12 September 2006

8. Balloon Scrap Reduction
Define: Reduce balloon scrap for major scrap code by 80%
Stable!
Measure: Length
BSC Six Sigma: ASQ Meeting – 12 September 2006

9. Balloon Scrap Reduction
Analyze: Designed Experiment
Improve / Control:
Mistake Proofing – only use preferred adhesive type!
60% scrap reduction!
BSC Six Sigma: ASQ Meeting – 12 September 2006

10. Business Process Improvement Roadmap - DMAIC
Define
What are you trying to accomplish?
Measure
How will you know the project has been successful?
Analyze
What elements in your process can be leveraged for improvement?
Improve
What is your improvement?
Control
What is your plan to implement and maintain the improvement?
Lean and Six Sigma both use the DMAIC roadmap as a common approach for process improvement
BSC Six Sigma: ASQ Meeting – 12 September 2006

11. Business Process Improvement
BSC Six Sigma: ASQ Meeting – 12 September 2006

12. Price Approval Process – Reduce Time, Increase Consistency
Measure
Collected data on time and logistics for price approvals
Analyze
Developed detailed process maps, identified waste and non-value added steps, identified gaps between ideal and current state
Improve
Developed target state, piloted tools for standardizing price approvals and automating repetitive tasks
Define
Defined goal, talked to the customers and started to understand process complexity
Control
Developed control plan, implemented and monitored new process
BSC Six Sigma: ASQ Meeting – 12 September 2006

13. Price Approval - Results
75% reduction in response time to customer
62% reduction in process steps
88% reduction in decision steps
Standardized processes: consistency, accuracy
Customer driven solution
“With BPI, our main focus was on our Customer and the requirements that they had. Without their feedback and keeping them our main focus, we would have probably come up with a totally different solution for the process of requesting and receipt of approvals” – Team Leader
BSC Six Sigma: ASQ Meeting – 12 September 2006

14. Does this product meet spec?
Lower Spec
Upper Spec
A: yes
B: no
C: maybe
D: not sure - phone a friend
BSC Six Sigma: ASQ Meeting – 12 September 2006

15. Measurement System Analysis: Gage R&R

16. The Basic Model
The total observed variation is equal to the real process variation plus the variation due to the measurement system.
BSC Six Sigma: ASQ Meeting – 12 September 2006

17. Effect of Measurement Variation
LSL
USL
Actual process variation - No measurement variation
LSL
USL
Total observed variation
- With measurement variation
BSC Six Sigma: ASQ Meeting – 12 September 2006

18. Gage R & R
Means of assessing the repeatability and reproducibility of a measurement system.
Evaluates how much total observed variation is due to the measurement device and measurement methods
LSL
USL
Measurement Variation vs. Actual Process Variation ?
BSC Six Sigma: ASQ Meeting – 12 September 2006

19. Gage R&R Example: Graphical Output
BSC Six Sigma: ASQ Meeting – 12 September 2006

20. Measurement System Terms
Stability
Accuracy
Precision
Resolution
Bias
Reproducibility
Linearity
Discrimination
Repeatability
Calibration
BSC Six Sigma: ASQ Meeting – 12 September 2006

21. Gage R&R Example: Graphical Output
At each table, identify ONE graphic that
best describes each term. 1 3 2 4 5 6
BSC Six Sigma: ASQ Meeting – 12 September 2006

22. Destructive Gage R&R Reference:
De Mast, Jeroen; and Trip, Albert (2005). “Gauge R&R Studies for Destructive Measurement”. Journal of Quality Technology 37 (1), pp
BSC Six Sigma: ASQ Meeting – 12 September 2006