Lean Six Sigma Project Mentoring Guide

Step
Number Questions: Deliverables % Complete Recommended Tools Comments

Who are your customers? High-Level Flow Chart Flow Chart, SIPOC
I-1
What does your customer
determine as value? COPQ Estimates Business Unit / Department IPO

High-Level Value Stream Map Value Stream Map

What are the key processes under
I-2 your control that deliver value to
I your customer? COPQ Flowdown Pareto Diagram, QFD
d
e
Pareto Diagram, FMEA,
n Identify and Prioritize Opportunities
Champion Interview
t
i Does the customer requirement
Build a Project Queue Prioritization Matrix
f align with a business case?
y I-3 How have you prioritized
improvement opportunities? Estimate Annual Financial Benefits Scorecard

Who will lead the project teams? Develop Annual Goals and
Scorecard
Milestones

Assign Champions, MBBs & Black

Project Contracts
Belts

10/25/2019 Printed 2010 Variance Reduction International, Inc. (VRI)

 Define: Questions: Deliverables Recommended Tools Comments
Who are your customers for the
assigned project? SIPOC SIPOC

1 Project Contract Project Contract

What is the business case?
What are the deliverables for the
project? Primary ands Secondary Metrics
QFD, Customer Interview
VOC/VOB
What Metrics to Capture?
What are the major steps in the Macro Process Flow Flow Chart
D process?
2 Scope of Project / Boundaries
e Does the project need to be Potential Project Spins Offs into the Cascading IPO
f scoped? ProjectQueue
How have you prioritized
i improvement opportunities?
n Identify and Proiritize Opporunities Pareto Charts, FMEA
e

Stakeholder Analysis Stakeholder Analysis

3
Who are the stakeholders in the Project Contract / Signature
process? Project Contract / Signature Page
Page

Who are the team members

working on these improvements?
Project Plan or Kaizen Plan Gantt Chart, Kaizen Plan
What are the goals and timeline for
the project? Is this an opportunity
for a Kaizen?

10/25/2019 Printed 2010 Variance Reduction International, Inc. (VRI)

 Measure: Deliverables Recommended Tools Comments

What is the current state of the

Process Flow Diagram, Value
process?
4 Current State Map Stream Map, Physical flow map,
Contstraint Map, OEE.
Is the process constrained?
M
How is the process measured? Is
e 5 the measurement precise?
Assessment of Measurement
Measurement System Analysis
System
a Accurate?
s Data Collection, Histogram, Run
What is the baseline for the key Process Baseline Charts, Control Charts, Box Plot,
u performance metrics? OEE
r 6
What are the specifications of the Capability Study (Product
e process? Is it capable? Process Capability Capability, Cpk Charts),
Customer Interview

7 What is the Cost of Poor Quality? COPQ Cpk, dpm, cost data

Analyze: Deliverables Recommended Tools

Comments

Kaizen, Takt time, 5S, Process

Prioiritized list of 9 Classic Lean Flow Diagram, Value Stream
Wastes Map, Physical flow map, Layout
What types of waste are apparent Design, OEE
in the process?
8
Are the primary metric(s) off-target. Cause and Effect Diagram,
Does it exhibit high variation? Pareto Chart, Regression,
A Factors that move the mean or Control Charts, Pareto analysis,
n cause variation. ANOVA, correlation analysis,
DOE, t-tests, F-tests, Chi-
a Square tests
l
y FMEA, 5 Whys, Reality Tree,
z Cause Mapping, OEE, Cause
and Effect Diagram, Pareto
e What are the sources of the
9 Root Causes of the Problem Chart, Regression, Control
problem? Root causes?
Charts, Pareto analysis, ANOVA,
correlation analysis, DOE, t-
tests, F-tests, Chi-Square tests

10/25/2019 Printed 2010 Variance Reduction International, Inc. (VRI)


What would a benchmark or “world
10
class” process look like?
Customer Interview Form
(VOC), Champion Interview
Project Goals
(VOB), Benchmark study, Run
Charts

10/25/2019 Printed 2010 Variance Reduction International, Inc. (VRI)

 Improve: Deliverables Recommended Tools
Comments
Kaizen,
How can we remove the cause of
the waste? Possible Solutions:
5S, Visual Controls, Takt Time,
Line Balancing, Single Piece
Proposed Solutions
Flow, Pull Systems, Layout
Design, Quick Changeover,
TPM, Poka Yoke, Standard
11 Work

How do the inputs to the process Inputs related to Outputs on IPO Scatter Plots, Modeling, DOE
affect it? Do they interact?
I
m Prioritization Matrix, Solution
p Grid, Customer Interview, DOE,
Selected Solutions Scatter Plots, Pugh Selection
r What is the list of improvements to
Matrix, Bulleted List of
12 be made? Are tests necessary? Is
o there a risk in implementing them? Improvements
v
Future State FMEA and VSMs FMEA, VSM
e

5S, Visual Controls, Takt Time,

Line Balancing, Single Piece
Flow, Pull Systems, Layout
Implemented Solutions
Design, Quick Changeover,
TPM, Poka Yoke, Standard
What is the performance of the Work, Process Changes
13 improved process? Did you meet
your goal?
Capability Study (Product
Capability, Cpk Charts),
Hypothesis Testing, Data
Re-assessment of Capability
Collection, Histogram, Control
Charts, Run Charts, Box Plot,
OEE

10/25/2019 Printed 2010 Variance Reduction International, Inc. (VRI)

 Control: Deliverables Recommended Tools
Comments
Control Charts, Control Plans,
How will you sustain the
14 Control Plan Error proofing, Accountability,
improvement?
5S audit
C
o Validated Financial Benefits
COPQ Tracking, Financial
Verification
n
What is the benefit from the Complete Project Presentation,
t Documented Results
Project Database
15 improved process? Is it
r documented?
Communication Plan, Project
o Documented Scalable Projects Database, Complete Project
l Presentation

Reward and Recognition

16 Has the team been rewarded? Team Recognition
Policies

10/25/2019 Printed 2010 Variance Reduction International, Inc. (VRI)