Lean Six Sigma

Fundamentals
ISEE – 582 / 682
Project Template
Team Members
 | 2

Team Project Submissions

 Project Charter (15 pts)
 Define Phase (16 pts)
 Measure Phase (16 pts)
 Analyze Phase (16 pts)
 Improve Phase (16 pts)
 Control Phase (16 pts)
 Total Project including a 1-page Abstract / Executive Summary as a
PDF document (5 pts)
Note 1: Every phase needs to include a minimum of 3 deliverables from “Deliverables” sheets.
Note 2: Each group should submit 3 separate documents:
1. one-page abstract (PDF) | 2. Project Charter (PDF) | 3. Presentation (PPTX)
 | 3

Project Charter (15 pts)

 Include a summary of project charter at the beginning of your presentation
(~3 slides) covering the following 6 sections (10 pts). Also, submit the completed
Project Charter (available in word format in MyCourses, tab of PROJECT). (5 pts)
 Problem Statement:
• A high-level statement defining and quantifying the problem
 Project Objective:
• A brief statement identifying project goals
 Project Scope:
• The boundaries (start / end) of the process that is associated with the
project
 | 4

Project Charter
 Response Variable:
• Output with units and measurement source
 Defect Definition:
• Defined with respect to response variable
 Quantification of Problem:
• Conditions: Attributes negatively impacting response variable
• Extent: Quantitative measures of effect
• Performance: Execution relative to business need
• Time Frame: Time period of data set that is being study
• Specifications: Customer CTQ, specifications or expectations
 | 5

DEFINE – Slide 1 (4pts) DEFINE

 Identify the 3 tools chosen. Explain how/why did you

choose them.
 | 6

DEFINE – Slide 2 (4pts) DEFINE

 Show tool 1 and results

 What is take away
 | 7

DEFINE – Slide 3 (4pts) DEFINE

 Show tool 2 and results

 What is take away
 | 8

Tool 3: Cause and Effect DEFINE

 Spending more than the monthly budget.

Food Entertainment

Excessive
Spending
 | 9

MEASURE – Slide 1 (4pts) MEASURE

 Identify the 3 tools chosen. Explain how/why did you

choose them.
 | 10

MEASURE – Slide 2 (4pts) MEASURE

 Show tool 1 and results

 What is take away
 | 11

MEASURE – Slide 3 (4pts) MEASURE

 Show tool 2 and results

 What is take away
 | 12

MEASURE – Slide 4 (4pts) MEASURE

 Show tool 3 and results

 What is take away
 | 13

ANALYZE – Slide 1 (4pts) ANALYZE

 Identify the 3 tools chosen. Explain how/why did you

choose them.
 | 14

ANALYZE – Slide 2 (4pts) ANALYZE

 Show tool 1 and results

 What is take away
 | 15

ANALYZE – Slide 3 (4pts) ANALYZE

 Show tool 2 and results

 What is take away
 | 16

ANALYZE – Slide 4 (4pts) ANALYZE

 Show tool 3 and results

 What is take away
 | 17

IMPROVE – Slide 1 (4pts) IMPROVE

 Identify the 3 tools chosen. Explain how/why did you

choose them.
 | 18

IMPROVE – Slide 2 (4pts) IMPROVE

 Show tool 1 and results

 What is take away
 | 19

IMPROVE – Slide 3 (4pts) IMPROVE

 Show tool 2 and results

 What is take away
 | 20

IMPROVE – Slide 4 (4pts) IMPROVE

 Show tool 3 and results

 What is take away
 | 21

CONTROL – Slide 1 (4pts) CONTROL

 Identify the 3 tools chosen. Explain how/why did you

choose them.
 | 22

CONTROL – Slide 2 (4pts) CONTROL

 Show tool 1 and results

 What is take away
 | 23

CONTROL – Slide 3 (4pts) CONTROL

 Show tool 2 and results

 What is take away
 | 24

CONTROL – Slide 4 (4pts) CONTROL

 Show tool 3 and results

 What is take away
Definition and Deliverable Slides
For Reference only
 | 26

Define
Define Problem
Problem
• Quantitative problem statement

DEFINE • Time frame of variation

• Impact to business
• Cost of Poor Quality estimate
• Defect

Identify Customer

• Internal or External
f ect /
e
e r, d Q Identify Cost to Quality

s t om d CT • Voice of Customer
u
t i fy c ns an • Process not meeting CTQ
n o
Ide ariati
• Defect and/or variations
v
High Level Process Map

• Current process “as is”

Scope Project

• Target defect / variation reduction

• Financial benefit goal
• Narrow scope
• Team members
• Project definition
 | 27

Define Deliverables
 Team identified  Project charter
 Customer identified  Pareto of defects (if available)
 CTQ identified  Voice of customer identified
 Problem statement completed  Defect to be reduced
 Project scope  Process impacting CTQ
 Review project objective with team  High level process map
 Review project objective with  Project plan
process owner  Any red flags
 DPMO (baseline and target)  Next steps
 COPQ estimate
 | 28

Detail Process Map

• Process inputs / outputs

Measure • True process flow

Rolled Throughput Yield

• Opportunities for improvement

• Hidden factory

t put
d ou h a Data Collection Plan
n
t a tablis
p u • Correct data and sample size to be collected

t i fy in nd es
n a e
Ide bles selin
Measurement System Analysis
ia ba
var • Can it detect variation and see improvements

Collect Data

Graphical Analysis

• FMEA, Fishbone, etc

Baseline Analysis

• Cp, Cpk, DPMO, Sigma score


Measure Deliverables
 Rolled Throughput Yield calculated
 DPMO score calculated
 Detailed process map or value
stream map
 VOC identified and completed
 Process characterized
 Basic control charts
 COPQ – refined
 C&E Diagram, FMEA
| 29
 Measure system analysis
completed, issues identified.
 Data collection plan completed
 Process performance baseline
 Preliminary graphical analysis of
data
 Project plan tracked and updated
 Any red flags with project or scope
 Next steps
 | 30

Multi-vari Studies
Analyze • Identifies variables needing further analysis

nd Analytical Tools
ut a
y inp es,
f y ke riabl ship, • Trends and behaviors
nti va on
Ide tput relati s if
• Graphical analysis

ou tand mine nt
d e rs eter nifica
un and d l sig Correlation and Regression
ti s tica
sta • If know “X”, predict “Y”

Hypothesis Testing

• Attribute data (Proportions, Chi Square)

• Variable data (Means, Standard Deviation, ANOVA)

Analyze Deliverables
 Revised problem statement if
necessary
 Revised detailed process map if
necessary
 Sources of variation quantified and
prioritized
 Display data to identify and verify
the “vital few” factors
 Sampling plan
 Graphical analysis and
interpretation of data
| 31
 Correlation and regression
 Hypothesis statement(s), null
hypothesis and alternative
hypothesis
 Minitab hypothesis test output, p
value and interpretation
 Project management update
 Any red flags with project and
scope
 Next Steps
 | 32

Improve Design of Experiments

• Best combination of inputs and outputs to meet or exceed

dates the CTQ.
i
d val ing
s an erat
tif i e op s
n m
Ide ptimu dition
o con Validate Improvement

• Pilot test improvement

• Ensure optimum inputs results in desired outputs

Improve Deliverables
 FMEA
 Display data to identify and verify
the “critical” factors (KPIVs)
 DOE or regression sampling plan
 Graphical analysis and
interpretation
 Detailed process map of optimum
process
| 33
 Cost / benefit analysis of proposed
Alternative solution(s)
 Validate improvements
 Project management update
 Any red flags with project and
scope
 Next Steps
 | 34

Statistical Process Control (SPC)

• Monitors process improvement

Control
• Attribute Data (U and P charts)
• Variables Data (I-MR chart, Xbar-R chart)

Control Plan
• Parameters of Operation
• Responsibility
• Actions and Preventative Maintenance

tains Reaction
Reaction Plan
Plan

m ain nts
nd veme
• When to react and actions to take
a • Who can take action

n i tors impro
Mo cess Long Term Measurement System Analysis Plan

pro • Data collection and review

Training
Training
• Standard Operating Procedures

Change
Change Control
Control
• Procedures for approving changes

Sustain
Sustain Expectations
Expectations
• Management commitment to control strategy.
 | 35

Control Deliverables
 Detailed process map or value
stream map of recommended
process
 Completed and approved control
plan
 Control charts verifying process is
in control.
 Project is documented
 Training schedule
 Audit plan
 Reaction plan
 Change control in place
 Long term MSA and capability
analysis
 Cost / benefit analysis of new
process
 Completed project management
report
 Any red flags with project or
implementation
 Next Steps identified
 Team recognition