S.

Natarajan 25 Sep 2004

Sixth set of Questions for six sigma programme (DLP) :

1. Why at all do I require Process mapping & will it be required for all
projects?

Process mapping clearly identifies the flow of information , materials and

activities

In a nutshell the map helps to demarcate process boundaries and helps in

value added flow of all the above

It is also an input for preparing a value added FMEA, MSA & Control plan

It helps for the transition from as-is to to-be

Process mapping is required for all projects

2. How do we decide the starting and end point of our process map?

The starting point & ending point of the process is decided by the team based
on iterations and consensus and by building one piece at a time

3. How do I get the S, O, D Nos. for Non Manufacturing processes?

For each process step / input variable list the ways it can go wrong – failure
mode

After that evaluate the effect of the failure mode , causes for the failure mode
and the current controls – prevention & detection

Assign severity rating for the effect , occurrence rating based on the data for
failure mode & causes and the detection rating based on the current controls
– detection

Then calculate RPN which is SxOxD for both failure mode and for causes
4. Prepare a list of concepts, their sequence and approximate time
spent on each to ensure that the entire discussion of FMEA is
completed in 2 hours time.

For each process step / input variable list the ways it can go wrong – failure
mode – 5 minutes

After that evaluate the 4 effects of the failure mode . Assign critical
characteristic symbol in the class column , if the severity number > 8 - 20
minutes

Assign occurrence rating based on the data for failure mode & causes or
based on capability studies or similar product data - 25 minutes

If Sev 5-8 / Occurrence 4-10 , then assign significant characteristic symbol in

the class column - 5 minutes

Fill in current controls for prevention of cause , detection of cause and

detection of failure mode - 25 minutes

Assign detection rating based on the current controls – detection - 5

minutes

Then calculate RPN which is SxOxD for both failure mode and for causes –
10 minutes

Go for recommended actions in the following order – reduce RPN if it is a

critical characteristic , reduce RPN for the failure modes which are top in the
pareto & reduce RPN for significant characteristics . Calculate estimated
RPN and validate after initiating actions – 25 minutes