Program Nam

Lean Six Sigm

<Project Title
(State From ... To)>
< Last Name, First Name >
DefineMeasure
AnalyzeImproveControl
Wave No: <xx>
Review Date: <xx/xx/xxxx>

LEAN
SIX SIGMA
 Define
Define Phase Road Map
Define Measure Analyze Improve Control

Activities Tools
• Team election and scoping • Project Charter
• Review Project Charter • Voice of the Customer and Kano
• Validate High-Level Value Stream Map and Analysis
Scope • SIPOC Map
• Validate Voice of the Customer • Project Valuation/ROIC Analysis Tools
and Voice of the Business • RACI and Quad Charts
• Validate Problem Statement • Stakeholder Analysis
and Goals • Communication Plan
• Validate Financial Benefits • Effective Meeting Tools
• Create Communication Plan • Inquiry and Advocacy Skills
• Select and Launch Team • SWOT Analysis
• Develop Project Schedule • Time Lines, Milestones,
• Complete Define Gate and Gantt Charting
• Pareto Analysis

Bonacorsi Consulting 2
Measure Phase Road
Map
Measure

Define Measure Analyze Improve Control

Activities Tools
• Identify Key Input, Process and Output •
High/Low level process Maps
Metrics •
Value Stream Map
• Develop Operational Definitions •
Operational Definitions
•
Data Collection Plan
• Develop Data Collection Plan
•
Statistical Sampling
• Validate Measurement System •
Measurement System Analysis (MSA), Gage
• Collect Baseline Data R&R
• Constraint Identification
• Determine Process Performance/Capability
• Setup Reduction
• Validate Business Opportunity • Generic Pull
• Value Stream Map for deeper understanding & • Kaizen
focus • TPM
• Control Charts
• Quick Wins (Control Plans)
• Process Capability, Cp & Cpk
• Measure Gate Review
Bonacorsi Consulting 3
 Analyze
Analyze Phase Road Map
Define Measure Analyze Improve Control

Activities Tools
• Identify Potential Root Causes • Process Constraint ID and Takt Time
• Reduce
Analysis
List of Potential Root Causes
• Cause & Effect Analysis
• Confirm Root Cause to Output Relationship
• FMEA
• Estimate Impact of Root Causes on Key
Outputs • Hypothesis Tests/Conf. Intervals
• Prioritize Root Causes • Simple & Multiple Regression
• Complete • ANOVA
Analyze Gate
• Components of Variation
• Conquering Product and Process
Complexity
• Queuing Theory

Bonacorsi Consulting 4
 Improve
Improve Phase Road Map
Define Measure Analyze Improve Control

Activities Tools
• Develop Potential Solutions • Replenishment Pull/Kanban
• Evaluate, Select, and Optimize Best • Stocking Strategy
Solutions
• Process Flow Improvement
• Develop ‘To-Be’ Value Stream Map(s)
• Process Balancing
• Develop and Implement Pilot Solution
• Analytical Batch Sizing
• Confirm Attainment of Project Goals
• Total Productive Maintenance
• Develop Full Scale Implementation Plan
• Design of Experiments (DOE)
• Complete Improve Gate
• Solution Selection Matrix
• Piloting and Simulation

Bonacorsi Consulting 5
 Control
Control Phase Road Map
Define Measure Analyze Improve Control

Activities Tools
• Implement Mistake Proofing • Mistake-Proofing/
Zero Defects
• Develop SOP’s, Training Plan & Process
Controls • Standard Operating Procedures
(SOP’s)
• ImplementSolution and Ongoing
Process Measurements • Process Control Plans
• Identify
Project Replication • Visual Process Control Tools
Opportunities • Statistical Process Controls
• Complete Control Gate (SPC)
• Transition Project to Process Owner • Solution Replication
• Project Transition Model
• Team Feedback Session
Bonacorsi Consulting 6
Bonacorsi Consulting
This Training Manual and all materials, procedures and systems herein contained or
depicted (the "Manual"), are the sole and exclusive property of Bonacorsi Consulting,
L.L.C.
The contents hereof contain proprietary trade secrets that are the private and
confidential property of Bonacorsi Consulting. Unauthorized use, disclosure, or
reproduction of any kind of any material contained in this Manual is expressly
prohibited. The contents hereof are to be returned immediately upon termination of any
relationship or agreement giving user authorization to possess or use such information
or materials. Any unauthorized or illegal use shall subject the user to all remedies, both
legal and equitable, available to Bonacorsi Consulting. This Manual may be altered,
amended or supplemented by Bonacorsi Consulting from time to time. In the event of
any inconsistency or conflict between a provision in this Manual and any federal,
provincial, state or local statute, regulation, order or other law, such law will supersede
the conflicting or inconsistent provision(s) of this Manual in all properties subject to that
law. Steven Bonacorsi is a Senior Master
Black Belt instructor and coach.
© 2006 by Bonacorsi Consulting, L.L.C. Steven Bonacorsi
All Rights has trained
Reserved.
hundreds of Master Black Belts, Black
Belts, Green Belts, and Project
Sponsors and Executive Leaders in
Lean Six Sigma DMAIC and Design for
Lean Six Sigma process improvement
methodologies.

Bonacorsi Consulting 7