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Project name

Define Measure Analyze Improve Control Define your business problem Measure your process (Y) performance Find the root causes (Xs) of the problem Improve, implement new solution Deliver Y performance over time

Define

1 Pb Statement

Description of the problem (what? where? since when? based on which data? Based on which facts?) Voice Of Customer (Customer perception) Internal perception Competitors benchmark

2 Goal Statement

Develop Goal statement/opportunity or objective in clear, concise, measurable terms Demonstrate alignment of the project with the company/business strategy

Define

3 Business Case

Why to do the project? What if project not done? Financial Business Case

What Comment Cost

K Project Labor Project Materials Project Contractors Equipment investment Yearly operation cost TOTAL Costs Incremental Revenues Labor Savings Material Savings TOTAL Benefits (1 year)

ROI

Define

4 Project scope

Project: in scope Project: out of scope

5 Team

Customers: Others: Black Belt: Master Black Belt: VP Quality / Quality Manager:

6 Planning

Dates: Gantt

Define

7 (SIPOC)

Supplier = My Company

Input

Step 1

Step 2

Step 3

Output

My Customer

measurement

CTQ*

Definition Specification limit Performance targets

*Critical To Quality

Measure

Selected Project CTQ(s):

Discrete/continuous CTQ?

CTQ Operational Definition(s): What is it (measurement starting point and end point) ?

What is a defect?

Measure

Measurement system analysis

Data Collection plan for Repeatability & Reproductibility study: Data sample size = Date of data collection: Where data have been collected? How data have been collected? How many operators? How many repeats per operator? Gage R&R study Continuous data: -Tolerance (USL-LSL): -Short method (yes/no): -Gage R&R as %contribution: Gage R&R as %tolerance: Nb of distinct categories:

Gage R&R study discrete data: If we have a Known sample (a reference), then how was built the known sample?

Measure

CTQ data collection plan Data sample size = Date of data collection: Where data have been collected? How data have been collected?

Will you take the opportunity to collect obvious Xs when collecting your CTQ measurements? If yes, which Xs: Display an extract of the data collected:

Measure

Continuous CTQ Sample size= Short term data or Long term data? Histogram with Normality test result and descriptive statistics:

Non NORMAL Distribution Observed DPMO= Equivalent ZLT= Equivalent ZST (ZLT+1.5)=

PROCESS CAPABILITY MEASURE: NORMAL Distribution Observed DPMO= Potential DPMO= ZLT = ZST (ZLT+1.5)= Conclusion Problem with trend, variability or both?

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10

Measure

Discrete CTQ Sample size: Short term data or Long term data? Process capability Yield (%)= %defects= DPMO= Opportunities per unit= DPU= Equivalent ZLT= Equivalent ZST (ZLT+1.5)= 95% confidence interval on DPMO:

11

Analyze

Continuous CTQ Normal probability plot:

Conclusion (can we detect a true process and an unstable process?): All type of CTQ Stability over time/Run chart:

Conclusion: Pb of technology (short term common causes)? Pb of control (long term shift due to special causes)? Both pbs?

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12

Analyze

Improvement Goal Target (from benchmark) for: Trend: Variability: LT DPMO or LT %defects= Yield (%)= ZLT= ZST=(ZLT+1.5)=

6 Sigma tools necessary to meet performance objectives: Ground fruit: Logic and Intuition Low hanging fruit: Basic tools (Process Map, CE/CNX fishbone diagram, SOP, FMEA, Pareto, Histogram, Box plot) Bulk of Fruit Process Characterization and Optimization Sweet Fruit: Transform the project into a DFSS project

13

Analyze

Process (AS IS) detail analysis: Detailed process map

Conclusion Standard Operation Procedures analysis: Exist: Are applied: Incitation to apply them exist: Training has been given to operators: Policy analysis: Exist Are applied

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14

Analyze

List of potential significant Xs

Label C/N/X on your fishbone, then rate every X impact vs implementation (table below)

Fishbone diagram of my Y

Measurements Materials Men

Y/CTQ Output

Environment

Methods

Machines

1 3

2 4

Hard

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15

Analyze

Results of segmentation (continuous CTQ only) : (Box plots, Scatter plots, Distributions per X)

Conclusion:

16

Analyze

Pareto chart of the CTQ categories:

Conclusion: FMEA:

Conclusion:

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17

Analyze

Statistical Tests Performed

Test one sample or two sample T-test Annova one way Homogeneity of variance Chi square test Simple regression Non parametric data test ANOVA 2 ways GLM DOE screening Conclusion/Prioritized list of significant Xs: X Factors p value

%contribution

conclusion

18

Improve

List of Vital few Xs (screening DOE):

Improvement action plan (Who What When):

19

Improve

Transfer function:

I13

X tolerance settings:

20

Control

C-step 11: Define and Validate Measurement System on Xs (if necessary)

Control on one X (yes/no): If yes, X measurement system analysis:

Data Collection plan for Repeatability & Reproductibility study: Data sample size = Date of data collection: Where data have been collected? How data have been collected? How many operators? How many repeats per operator? Gage R&R study Continuous data: -Tolerance (USL-LSL): -Short method (yes/no):

Nb of distinct categories:

Gage R&R study discrete data: If we have a Known sample (a reference), then how was built the known sample?

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21

Control

C-step 12: Determine new Process Capability

Process or Product new capability: Continuous CTQ: NORMAL Distribution Observed DPMO= Potential DPMO= ZLT = ZST (ZLT+1.5)=

Non NORMAL Distribution Observed DPMO= Equivalent ZLT= Equivalent ZST (ZLT+1.5)=

Discrete CTQ: Sample size:= Short term data or Long term data? Process capability Yield (%)= %defects= DPMO= Opportunities per unit= DPU= Equivalent ZLT= Equivalent ZST (ZLT+1.5)= 95% confidence interval on DPMO

22

Control

C-step 13: Implement Process Control

Control Charts (SPC) in place/review mechanisms:

23

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