mahindra black belt project template - new
TRANSCRIPT
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Lean Sigma Project
Dated: ____ / ____ / ________
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Define
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Buine !pportunity
y1 y2 y3 y4
x1.1 x1.2 x1.3
x1.1 x1.2 x1.3
x1.1 x1.2 x1.3
x1.1 x1.2 x1.3
"op Le#el $ %Big $& 'mpact een at
!perational Buine Le#el
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(ritical to Quality and (ritical to Proce()art
Critical to
Quality
Critical
customerrequirement
Customer
issues
Voice of
customer
Voice ofbusiness
Businessissues
Criticalbusiness
requirement
Critical forprocesses
*emar+1. Voice of customer and voice of business to be prioritized to tose !ic are related to pro"ect ob"ective2. #se V$B or V$C or bot dependin% on te pro"ect ob"ectives
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"eam ()arter
Project "itle
Buine (ae !pportunity Statement
&ain
'mpact of pain in (s. )or soft*
+i%ma ,evel
,oal tatement Project cope
Metric Currentlevel
Goal /Target
Target date &rocess under improvement-
+tarts !it
nds !it
Project plan "eam Selection
Phase Start End Remarks
/efine Campion-
0easure B BB
nalyze 0ember
'mprove 0ember
Control 0ember
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Miletone Sc)edule
P)ae Acti#ityno
Acti#ity Decription Plannedtart
Actualtart
Plannedcompletion
Actual(ompletion
Sign off -y()ampion
Sign off-y "QM'
/ /1 Business impact/2 eam Carter
/3 V$C5CC(5CQ6 V$B5CB(7C&
/4 +'&$C
/8 /C
/9 :/C /etailed &rocess map
/; &rocess Quic=
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Miletone Sc)edule %(ontd.&
P)ae Acti#ityno
Acti#ity Decription Plannedtart
Actualtart
Plannedcompletion
Actual(ompletion
Sign off -y()ampion
Sign off-y "QM'
1 #se &areto and stratify ys 2 (edo 'si=a!a dia%ram
3 Carry out &rocess :0
4 xtract Quic= !ins
8 mploy Comparative metods to analyse data
9 Base line performance of xs and setimprovement %oal for eac x
; :ix 'mprovement %oal for eac selected x
'1 carryout affinity dia%ram
'2 /o +olution mappin% six tin=in% ats
'3 +elect solutions
'4 &ilot te solution
'8 Validate te improvement
C1 'mplementation &lan
C2 (evie! and release :/&
C3 (edo :05'ntroduce 0ista=e proofin%C4 'nstall Control Carts
C8 0onitor xs
C9 1.'nte%rate !it '+$ system
C; &repare for pro"ect closure and reco%nition
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S'P!( D'A,*AM
Supplier 'nput Proce !utput (utomer
0a"or step 1
0a"or step 2
0a"or step 3
0a"or step 4
Proce ame+tartin% point-
nd point-
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&ro"ect title
"op Down ()art for P*!(0SS
+tartin% point-nd point-
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1unctional Deployment ()art
Step 1unction / *eponi-ility
1unction23 1unction24 1unction25 1unction26 1unction27 1unction28 1unction29
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C E
.
C E C E
.
C E C E C E
E E E E E E
C E
E
(urrent alue Stream Map
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Proce !-er#ation
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Proce Data (ollection 1orm
; i Pl i
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Phase 1
Evaluation
Phase 2
Planning
&
Preparation
Phase 3
Event
Phase 4
Follow-up
---Weeks -- Week On going
;ai
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Qualitati#e Analyi
Sr= o= Acti#ity (utomer
alue added
!perational
alue added
on2#alue
Added
&ro"ect itle-&ilot &ro"ect-
Q alitati e Anal i
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&ro"ect itle-&ilot &ro"ect-
+r.
Fo.
+ource Concerns
'ssues
&otential
Quic= !inopportunity)solution*
asy to
implement
:ast to
implement
Ceap to
implement
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Quic+ >in 'mplementation Plan
S= o= Quic+ win Acti#itie *eponi-ilitie
Peron
Start
Date
"arget
date ofcompletion
Actual
date ofcompletion
Standardi
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1uture alue Stream Map
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C E
.
C E C E
.
C E C E C E
E E E E E E
C E
E
1uture alue Stream Map
Quic+ >in *eult
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Quic+ >in *eult
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Meaure
')i+awa Diagram %(aue and 0ffect Diagram&
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')i+awa Diagram %(aue and 0ffect Diagram&
Major (ategorie of caue of Pro-lem Statement
Pro-lemStatement
Mac)ine%,eneric (ategory&
Material%,eneric (ategory&
0n#ironment%,eneric (ategory&
(aue
Su-2(aue
People%,eneric (ategory&
Met)od%,eneric (ategory&
Cause5ffect 0atrix
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Cause5ffect 0atrix
!utput ?3 !utput ?4 !utput ?5 !utput ?6 !utput 'ndicator
'nput &rocessindicators
Correlation of input to output otal
Scale: @one 3Low 5Moderate CStrong
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Sl= o= Performance 'ndicator %$& !perational definition
1
2
3
4
Sl= o= Proce / input indicator %& !perational definition
@1
@2
@3
@4
..
..
(emar=s-
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Data Meaurement Plan
(emar=s-$ter data refers to additional information from stratification perspective.
Performancemeaure %$&
!perationaldefinition
Data ourceand location
Sample
i)o will
collect t)e data
>)en willdata -e
collected
Eow willdata -e
collected
!t)er data t)at)ould -e collected
at t)e ame time
Proce /'nput %&
!perationaldefinition
Data ourceand location
Sample
i)o will
collect t)e data
>)en willdata -e
collected
Eow willdata -e
collected
!t)er data t)at)ould -e collected
at t)e ame time
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(arryout MSA
a reFuired
Data collection 1ormat %Modify a per
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% y preFuirement&
Data Summari
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% &
1ir continuou %$&
!utput indicator A#erage Standard de#iation (p (p+ Sigma Le#el1
2
3
Ge Eitogram BoH Plot 'ndi#idual c)art a appropriate %pate output of Minita-/ Sigma L&
1ir dicrete %$&
!utput indicator o= of unit o= of opportunitie per unit o= of defect DPM! Sigma Le#el
1
2
3
Summary Data %ue decripti#e tatitic in Minita- / Sigma L&
Baeline definition
>or+)eet for (alculating
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Sigma Performance continuou data
1. La-el t)e normal cur#e wit) t)e following:
2. Determine Area 3 :
:ind H1
,oo= up H1 in Formal able
rea 1 E 1 I ,oo= #p
3. +=ip tis step if tere is no ,+,Determine Area 4 -
:ind H2
Form /ist )H1* E Formal able ,oo= #p for H1
rea 1 E 1 I Form /ist )H1* E 1 I ) *
E .982319
E .;42?1
E .28;??
E
Calculatin% +i%ma &erformancenter
/elete if no #+,
/elete if no ,+,
@bar
+
#+,
,+,
9.;
.1833
9.>
.98 +i%ma
( ) ( )( )−
=
−
=
s
xUSL Z
1
( ) ( )( )
−
=
−
=
s
xUSL Z
2
>or+)eet for (alculating
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Sigma Performance continuou data
:ind H2
,oo= up H2 in Formal able
rea 2 E ,oo= #p
4. Determine "otal Area
8. $ield 3 I "otal Area
9. Proce Sigma (ome from"a-le Loo+up of yield
Form /ist )H2* E Formal able ,oo= #p for H2
rea 2
E F
E F
E .28;??
E .;42?1E;4.2?1J
E .98
E F
otal rea E rea 1 K rea 2 E ) * K ) *
ield E 1 I otal rea E 1 I ) *E x 1J
+i%ma+ E ,oo=up value in +i%ma able
( ) ( )( )−
=
−
=
s
X LSL Z
2
>or+)eet for (alculating Sigma Performance
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1. Fumber of units processed
2. otal number of defects made)'nclude /efects made and ,ater :ixed*
3. Fumber of defect opportunities per unit
4. +olve for defects per million opportunities
8. ,oo= #p process si%ma in abrid%ed si%maconversion table
0nter
FE 8
/E 8;
$E 33>
+i%maE 3.2;
Proce Baeline for Lean Project
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&rocess steps-
a=t (ate or a=t ime-
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Analy
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&rocess product :0 /ate )$ri%inal*
:0 eam )(evised*
Blac= belt reen belt &a%e- $f
&rocess ctions (esults
&rocesssteps requirem
ents
&otentialfailure
mode
&otentialeffects of
failure
+everity&otentialcause)s*
of failure
$ccurrence
Currentcontrols
/etection
(is=priority
number
(ecommended
action
(esponsibility andtar%et
completion date
ctionta=en
+everity$ccurrence
/etection
(is=priority
number
ext ext ext Fumber ext Fumber ext Fumber calculation
ext ext ext Fumber Fumber Fumber Calculation
Pareto Analyi %'f $ i dicrete data&
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Add Pareto Diagram here
(oncluion:
0ulti5vari nalysis )'f is Continuous data*
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dd ree /ia%ram and 0ulti5vari Cart ere
(oncluion:
alidation of
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Validate eac of te prioritized @ usin% tools li=e Comparative
0etods and Correlation. $ptimize usin% /$ as needed.
(oncluion:
alidation of
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:or lean pro"ects6 identify ime rap Constraints. #se ime
Value 0ap or a=t time carts.
(oncluion:
Summary of alidated
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S= o= identified a important from 1M0A / (0 MatriH alidated %$/& "ool Ged *emar+ %attac) Minita- /Sigma L output&
1
2
3
4
8
9
;
>
?
1
11
12
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'mpro#e
Lit Poi-le Solution %Ge tool li+e Braintorming lateral t)in+ing iH
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%Ge tool li+e Braintorming lateral t)in+ing iHt)in+ing )at etc=&
S= o= #alidated Poi-le olution
1 1.1
1.2
1.3
1.4
1.8
2 2.1
2.2
2.3
2.4
2.8
3 3.1
3.2
1uture alue Stream Map %SM&
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C E
.
C E C E
.
C E C E C E
E E E E E E
C E
E
Project / Action out of 1uture SM
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1or Lean Project Lit Poi-le Solution%Ge tool li+e 7S Set up reduction >or+ control ytem=&
'f you ue 7S
o= of red tag puto= of red tag addreed
State Before and After %)ow p)otograp)/ picture&
Standard met)od/ c)ec+ lit of cleaning etc=
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'f you ue Set up reduction ue t)e flow c)art=
(laify t)e tep a Kin erie %internal& or Kparallel %eHternal&
Define )ow eHternal were con#erted to internal
And )ow internal were made more efficient
S)ow tate of et up time -efore and after=
1or Lean Project Lit Poi-le Solution%Ge tool li+e 7S Set up reduction >or+ control ytem=&
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'f you ue >or+ (ontrol Sytem
1ollow tep gi#en on page 96 %ection 6=6&
1or Lean Project Lit Poi-le Solution%Ge tool li+e 7S Set up reduction >or+ control ytem=&
Solution election MatriH %(aue23&
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+i%ma impact ime impact Cost benefit impact $ter impacts valuation criteria
1 > 9 'mportance
5+olution5 Correlation of solution to criteria 5otal 5 %ent ? ? 3 1>
Solution election MatriH %(aue24&
+i%ma impact ime impact Cost benefit impact $ter impacts valuation criteria
1 > 9 'mportance
5+olution5 Correlation of solution to criteria 5otal 5 %ent ? ? 3 1>
Solution election MatriH %(aue25&+i%ma impact ime impact Cost benefit impact $ter impacts valuation criteria
1 > 9 'mportance
5+olution5 Correlation of solution to criteria 5otal 5 %ent ? ? 3 1>
Pilot implementation planning
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"a+ Acti#itie *eponi-le peron Start Date Due Date Statu andAction
+cope of pilot -
ime line-
*eult %attac) )eet from Minita- or Sigma L&
!utput indicator A#erage Standard de#iation (p (p+ Sigma Le#el DPM! Action Plan
1
2
3
1ailure Mode J 0ffect Analyi to confirmany concern in olution -eing propoed=
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y g p p
&rocess product :0 /ate )$ri%inal*
:0 eam )(evised*
Blac= belt reen belt &a%e- $f
&rocess ctions (esults
&rocesssteps requirements
&otentialfailure
mode
&otentialeffects offailure
+everity&otentialcause)s*of failure
$ccurrence
Currentcontrols
/etection
(is=prioritynumber
(ecommendedaction
(esponsibility andtar%etcompletion date
ctionta=en
+everity$ccurrence
/etection
(is=prioritynumber
ext ext ext Fumber ext Fumber ext Fumber calculation
ext ext ext Fumber Fumber Fumber Calculation
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(ontrol
1ull Scale 'mplementation Plan
"a+ Acti#itie *eponi-le peron Start Date Due Date Statu and
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"a+ Acti#itie *eponi-le peron Start Date Due Date Statu andAction
'mplementationstrate%y
+equential &ased &arallel :lat )/etails to be added*
ime line-
*eult %attac) )eet from Minita- or Sigma L&
!utput indicator A#erage Standard de#iation (p (p+ Sigma Le#el DPM! Action Plan
1
2
3
>or+)eet for (alculatingSigma Performance continuou data
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Sigma Performance continuou data
1. La-el t)e normal cur#e wit) t)e following:
2. Determine Area 3 :
:ind H1
,oo= up H1 in Formal able
rea 1 E 1 I ,oo= #p
3. +=ip tis step if tere is no ,+,Determine Area 4 -
:ind H2
Form /ist )H1* E Formal able ,oo= #p for H1
rea 1 E 1 I Form /ist )H1* E 1 I ) *
E .982319
E .;42?1
E .28;??
E
Calculatin% +i%ma &erformancenter
/elete if no #+,
/elete if no ,+,
@bar
+
#+,
,+,
9.;
.1833
9.>
.98 +i%ma
( ) ( )( )−
=
−
=
s
xUSL Z
1
( ) ( )( )
−
=
−
=
s
xUSL Z 2
>or+)eet for (alculatingSigma Performance continuou data
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S g a e o a ce co t uou data
:ind H2
,oo= up H2 in Formal able
rea 2 E ,oo= #p
4. Determine "otal Area
8. $ield 3 I "otal Area
9. Proce Sigma (ome from"a-le Loo+up of yield
Form /ist )H2* E Formal able ,oo= #p for H2
rea 2
E F
E F
E .28;??
E .;42?1E;4.2?1J
E .98
E F
otal rea E rea 1 K rea 2 E ) * K ) *
ield E 1 I otal rea E 1 I ) *E x 1J
+i%ma+ E ,oo=up value in +i%ma able
( ) ( )( )−
=
−
=
s
X LSL Z 2
>or+)eet for (alculating SigmaPerformance
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Performance
1. Fumber of units processed
2. otal number of defects made)'nclude /efects made and ,ater :ixed*
3. Fumber of defect opportunities per unit
4. +olve for defects per million opportunities
8. ,oo= #p process si%ma in abrid%ed si%maconversion table
0nter
FE 8
/E 8;
$E 3
3>
+i%maE 3.2;
Proce Performance for Lean Project
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&rocess steps- a=t (ate or a=t ime-
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Step 1unction / *eponi-ility
1unction23 1unction24 1unction25 1unction26 1unction27 1unction28 1unction29
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C E
.
C E C E
.
C E C E C E
E E E E E E
C E
E
1uture alue Stream Map%at t)e end of t)i Project&
Proce (ontrol Sytem
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Proce (ontrol Sytem
'nput Proce
outcome indicator
(ontrol limit ()ec+ing item 1reFuency *eponi-ilit
y
(ontingency
action plan
*emar+o be prepared for all output indicators and prioritized input process indicators !ic required monitorin% over time.
Mi t + P fi i t d d if
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Mita+e Proofing introduced if any
Add Mita+e proofing introduced wit) picture/ diagram if any
Vi l C t l i t d d if
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Visual Controls introduced6 if any
Add iual control introduced wit) picture/ diagram if any foreffecti#e trac+ing of $ and/ or lited in Proce control ytem=
( t l () t i t d d if
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Build QM competence | Application orientation | Spread QM | Build team culture | Quality a way of life
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Build QM competence | Application orientation | Spread QM | Build team culture | Quality a way of life
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