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Six Sigma Black Belt project Welcome Welcome! Please read this page (in particular) very carefully. Instructions The tabs (bottom of each sheet) in this document contain all of the deliverables expected of you. If you need help along the way, look for these special cells that have a red indicator in the corner. It looks like the Read me box to the right: Read me daniel-munson: Instructor: These cells contain some hints, tips, and self-checks. If you would like to print any of the tips, right click the cell containing the tip and select Edit Comment. Highlight the text, copy and paste in a any text document like WORD for printing. Simply slide your cursor over the red-cornered cell and you will get more information. The format for all of the deliverables is the same: The objective is in black font. It describes what you are doing the particular deliverable. The next segment is in green font. These are your instructions. The blue font is the data (where applicable) that you will need to complete the deliverable. Software We are using Excel software for the projects. You may use other software to complete your projects, but please report your answers in the Excel format described below. You may complete your assignments with any version of Excel software. All assignments can easily be completed with a basic copy of Excel. There is also an Add-In feature which is available for Excel that can be helpful, although it is not required. The Add-In feature comes free with each Excel package, although it may not be currently loaded into your copy of Excel. Following are the simple instruction for loading the Excel Add-ins for both Excel 2003 and Excel 2007. (Slide your cursor over the red-cornered cells to read) Excel 2003 or earlier Diane Johnson: Instructor: EXCEL 2003 or earlier Click on the TOOLS tab in the top bar of Excel. If your computer already has the “Data Analysis” option listed, you are ready to go. Your Data Analysis tools have already been added. Under the Data Analysis Function you will find some of the more advanced functions that we will be discussing such as ANOVAs, and t tests. If you do not see Data Analysis listed under the TOOLS tab, I encourage you to go to the Help function in Excel for specific instructions on how to load “the Data Analysis Toolpak” in your version of Excel. Here are the easy standard instructions for Excel 2003 if you need to load the Add-Ins. 1) On the Tools menu, click Add-Ins. 2) In the Add-Ins available box, select the check box next to Analysis Toolpak, and then click OK. 3) When you load the Analysis Toolpak, the DATA ANALYSIS command is automatically added to the TOOLS menu. If your version if slightly different than the above, refer to your HELP function for details on loading Tookpak. See the next spreadsheet at the bottom of this worksheet entitled EXCEL EXAMPLES for an illustration. The Data Analysis function in Excel is NOT required for the completion of this course. Excel 2007 or later Diane Johnson: Villanova instructor: Excel 2007 or later The Analysis ToolPak is a Microsoft Office Excel add-in program that is available when you install Microsoft Office or Excel. To use it in Excel, however, you need to load it first. 1. Click the Microsoft Office Button , and then click Excel Options. 2. Click Add-Ins, and then in the Manage box, select Excel Add-ins. 3. Click Go. 4. In the Add-Ins available box, select the Analysis ToolPak check box, and then click OK. If you get prompted that the Analysis ToolPak is not currently installed on your computer, click Yes to install it. 5. After you load the Analysis ToolPak, the Data Analysis command is available in the ANALYSIS group on the DATA tab. See the next spreadsheet EXCEL EXAMPLES for an illustration. The Data Analysis function in Excel is NOT required for this course. Excel Novice - Please read Diane Johnson: Instructor: It is beyond the scope of this Black Belt course to teach students how to perform all of the functions of Excel. The Microsoft web site has excellent FREE tutorials for Excel. https://support.office.com/en-us/article/Excel-training-9bc05390-e94c-46af-a5b3-d7c22f6990bb Or ask a business colleague who is proficient in Excel to show you how to do some of the basic things such as copying, cutting, pasting, copying from sheet to sheet, etc. Please do not expect your Black Belt class instructor to teach you how to use Excel software. That is not the objective of this course. This course will highlight specific Excel commands that are unique to Six Sigma, but it is not the objective of this course to teach basic Excel commands. Please use the suggested resources listed above. Project Timeline Remember that the entire project must be 100\% correct and complete by no later than midnight EST one week (7 days) BEFORE the last day of class. Deliverables include: Project charter (target week 3 or sooner) SIPOC (week 4 or sooner) Baseline sigma (week 7 or sooner) Pareto chart (week 8 or sooner) Expected Variation (week 9 or sooner) T Test (week 11 or sooner) Scatter diagram (week 12 or sooner) DOE (week 13 or sooner) Control chart (XmR) ( week 14 or sooner) Pp Ppk (week 15 or sooner) How to submit an Assignment In response to customers like you, we have added a peach-colored box for each deliverable. We have done this to make it clear (and consistent) the areas of the project that will be reviewed to your instructor. Project: Healthcare Project Deliverable: Improve phase - gen. sol. Student last name: Johnson What is the control chart telling you? There is a point out of control at subgroup #15. I would try to figure out why that happened. We would also recalculate the control limits because there is evidence the process has changed. What is the average of subgroup 1? 22 What is the average of subgroup 2? 34 What is the average of subgroup 3? 23 What is the average of subgroup 4? 22 What is the average of subgroup 5? 25 What is the average of subgroup 6? 23 What is the average of subgroup 7? 29 What is the average of subgroup 8? 27 VERY IMPORTANT!! Be sure to submit your assignments for grading as you complete each one and following the submission schedule for each deliverable- DO NOT WAIT UNTIL THE END OF THE COURSE TO SEND THEM ALL IN. NOTE THAT THE ENTIRE PROJECT MUST BE 100\% CORRECT BY ONE WEEK BEFORE THE END OF CLASS OR YOU WILL FAIL THE PROJECT AND THE COURSE. This means that you must submit ALL of your assignments far enough in advance of the project completion deadline to allow time for all necessary corrections to be made. Following the submission schedule is the best way to ensure that you have enough time to finish the project by the completion deadline - failure to meet the submission due dates can result in failing the course. Very few assignments are correct on the first submission and many require multiple rework attempts, so dont procrastinate! Excel examples This spreadsheet tab provides illustrations of adding the DATA ANALYSIS capability to your Excel software. If you see Data Analysis already listed under the Tools tab, you are set. If you do not see Data Analysis follow the instructions in the Green tab. Excel 2003 or earlier instructions Diane Johnson: Instructor: EXCEL 2003 or earlier Click on the TOOLS tab in the top bar of Excel. If your computer already has the “Data Analysis” option listed, you are ready to go. Your Data Analysis tools have already been added. Under the Data Analysis Function you will find some of the more advanced functions that we will be discussing such as ANOVAs, and t tests. If you do not see Data Analysis listed under the TOOLS tab, I encourage you to go to the Help function in Excel for specific instructions on how to load “the Data Analysis Toolpak” in your version of Excel. Here are the easy standard instructions for Excel 2003 if you need to load the Add-Ins. 1) On the Tools menu, click Add-Ins. 2) In the Add-Ins available box, select the check box next to Analysis Toolpak, and then click OK. 3) When you load the Analysis Toolpak, the DATA ANALYSIS command is automatically added to the TOOLS menu. If your version if slightly different than the above, refer to your HELP function for details on loading Tookpak. Remember that the Data Analysis function is NOT necessary for the course, but it is helpful. If you would like to print this tip, right click on the cell and select EDIT COMMENT. Then just highlight and copy the text, and paste in a document for printing. Excel 2003 or earlier versions of Excel example This spreadsheet tab provides illustrations of adding the DATA ANALYSIS capability to your 2007 Excel software. If you see Data Analysis already listed under the DATA tab, you are set. If you do not see Data Analysis follow the instructions in the Green tab. Excel 2007or later instructions Diane Johnson: Villanova instructor: Excel 2007 or later The Analysis ToolPak is a Microsoft Office Excel add-in program that is available when you install Microsoft Office or Excel. To use it in Excel, however, you need to load it first. 1. Click the Microsoft Office Button , and then click Excel Options at the bottom. 2. Click Add-Ins, and then in the Manage box, select Excel Add-ins. 3. Click Go. 4. In the Add-Ins available box, select the Analysis ToolPak check box, and then click OK. If you get prompted that the Analysis ToolPak is not currently installed on your computer, click Yes to install it. 5. After you load the Analysis ToolPak, the Data Analysis command is available in the ANALYSIS group on the DATA tab. Remember that the Data Analysis function is not required for the course. If you would like to print this tip, right click on the cell and select EDIT COMMENT. Then just highlight and copy the text, and paste in a document for printing. Diane Johnson: Instructor: EXCEL 2003 or earlier Click on the TOOLS tab in the top bar of Excel. If your computer already has the “Data Analysis” option listed, you are ready to go. Your Data Analysis tools have already been added. Under the Data Analysis Function you will find some of the more advanced functions that we will be discussing such as ANOVAs, and t tests. If you do not see Data Analysis listed under the TOOLS tab, I encourage you to go to the Help function in Excel for specific instructions on how to load “the Data Analysis Toolpak” in your version of Excel. Here are the easy standard instructions for Excel 2003 if you need to load the Add-Ins. 1) On the Tools menu, click Add-Ins. 2) In the Add-Ins available box, select the check box next to Analysis Toolpak, and then click OK. 3) When you load the Analysis Toolpak, the DATA ANALYSIS command is automatically added to the TOOLS menu. If your version if slightly different than the above, refer to your HELP function for details on loading Tookpak. Remember that the Data Analysis function is NOT necessary for the course, but it is helpful. If you would like to print this tip, right click on the cell and select EDIT COMMENT. Then just highlight and copy the text, and paste in a document for printing. Excel 2007 example THE PROJECT Healthcare Project A recent report from the Centers for Disease Control and Prevention indicates that over the past decade trips to emergency departments (ED) rose 20 percent, while the number of available emergency centers fell by 15 percent. Another study from the American Hospital Association indicated that 62 percent of hospitals feel they are at, or over, operating capacity. That number jumps to 90 percent when considering Level 1 Trauma Centers and larger (300+ beds) hospitals. These statistics are frighteningly familiar to many hospitals and patients. The pressures are mounting, and a faltering economy has swelled the ranks of uninsured -- people who often rely on the local ED for primary care. Countless emergency departments are literally on life support as they try to cope with capacity issues and workforce shortages. Preparing for or responding to emerging threats such as bioterrorism and SARS only increases the strain on the system. In hospitals across the U.S., EDs face a similar story of delays and dissatisfaction…from both patients and clinicians. Not all the news is bad, however. Some hospitals are finding new ways to overcome the challenges and create safer, more efficient environments. Through a combination of Six Sigma and Lean, hospitals are targeting critical aspects of patient flow, patient access, service-cycle time, and admission/discharge processes. A growing number of hospitals are taking steps to identify and remove bottlenecks or inefficiencies in the system. As a result, they are seeing a positive impact on patients, staff, and the bottom line. By using the principles you have learned in the Six Sigma Black Belt course we want to decrease door to doctor time in our ER to hopefully reduce the number of people who get tired of waiting and leave without treatment. In fact, last year of the 43,800 patients awaiting treatment, 6.3\% left without treatment--essentially because they were dissatisfied with the wait time. The nations emergency care network must remain strong -- not only to maintain its ability to serve basic community needs, but also to ensure it will have the necessary capacity and processes in place to respond quickly during a crisis. The deadline for having all project deliverables 100\% correct is 7 days prior to the end of the course Define (Project Charter) Objective: A problem statement needs to be developed. There needs to be a business case so that management will buy-in to having the team working on the project. The scope of the project also needs to be decided upon. This is important to ensure a likely successful completion. If the scope is too broad, a success may not be realized for years, or may not happen at all. Instructions for you: Create a project charter based Create a charter? daniel-munson: Instructor: Information about project charters can be found in recorded lectures in week 3, in your online textbook and study guides, and in the week 2 virtual class. upon the information in the introduction. (see The project tab) In reality, you would fill in a charter with team members names, stake holders, etc. We are not interested in those details for this simulation, but we do want to see what you come up with for four (4) items: Problem statement, business case, goal and project scope. TARGET ASSIGNMENT DATE - Submit in Week 3 or earlier Project: Healthcare Deliverable: Project charter Student last name: Your LAST name here What is the business case? (Use no more than 2 sentences.) Business Case? daniel-munson: Instructor: I am your sponsor for this project. If I was your actual sponsor, I would be very busy and would need to make decisions quickly. I would need to know what this project is all about and how it impacts the strategic objectives of the organization. Please limit this to a sentence or two. MAKE IS CLEAR AND CONCISE! What is the problem statement? (Use no more than 2 sentences.) Problem Statement daniel-munson: Instructor: Acting as your real-world sponsor, I would need to be sold on why we need to do this project. I wouldnt have time to read long explanations. I would need a short, to-the-point compelling reason why we need to do this. In the problem statement, we sell the need for the project with specific and measureable data. MAKE IT CLEAR AND CONCISE! What is the goal statement? (Use one sentence.) Goal Statement daniel-munson: Instructor: What is your target improvement for this project, including a target date? George Eckes mentions a 50\% improvement as a possible target for Six Sigma projects. Is a 50\% improvement enough in this case? Remember to link your goal to the problem statement and to keep your goal statement SMART! What is your project scope? (This is not your goal statement! Use one sentence.) The project scope? daniel-munson: Instructor: This needs a lot of thought. As your sponsor, I do not want to see scope creep. Whats scope creep?…please read on... The scope defines the boundaries of the project--usually some beginning point and ending point. For example, if I were leading a project to improve the delivery of course materials to students, I would have the following boundaries: The process (IN THIS PROJECT) starts: When the customers says, Yes, I am interested in enrolling. The process (IN THIS PROJECT) ends: When the customer receives the box from UPS that contains their handbook and CDs. The project stays within that confinement. Included might be: Enrollment process, warehousing process, accounting process, and UPS delivery process. What would NOT be included: -Errors in the handbooks or CDs. -User friendliness of the materials. Assumption and constraints regarding your team or budget may also be included in your scope statement. daniel-munson: Instructor: Acting as your real-world sponsor, I would need to be sold on why we need to do this project. I wouldnt have time to read long explanations. I would need a short, to-the-point compelling reason why we need to do this. In the problem statement, we sell the need for the project with specific and measureable data. MAKE IT CLEAR AND CONCISE! daniel-munson: Instructor: What is your target improvement for this project, including a target date? George Eckes mentions a 50\% improvement as a possible target for Six Sigma projects. Is a 50\% improvement enough in this case? Remember to link your goal to the problem statement and to keep your goal statement SMART! daniel-munson: Instructor: Information about project charters can be found in recorded lectures in week 3, in your online textbook and study guides, and in the week 2 virtual class. daniel-munson: Instructor: I am your sponsor for this project. If I was your actual sponsor, I would be very busy and would need to make decisions quickly. I would need to know what this project is all about and how it impacts the strategic objectives of the organization. Please limit this to a sentence or two. MAKE IS CLEAR AND CONCISE! DO NOT SEND ANY EXTRA ATTACHMENTS UNLESS YOUR INSTRUCTOR SPECIFICALLY ASKS YOU TO!! Please hand-in your assignments throughout the course. DO NOT SAVE THEM FOR THE END. The deadline for having all project deliverables 100\% correct is 7 days prior to the end of the course. Define (SIPOC) Objective: We want to view the process from a high level in order to see the major process elements. SIPOC - Suppliers, Inputs, Process, Outputs, Customers Instructions for you: Create a SIPOC map of the process based upon the healthcare case study write-up (found at The project tab). Feel free to use your imagination in doing this piece of the project. Draw upon your own experience from visiting an Emergency Department to come up with the suppliers, inputs, process, outputs, and customers. Note: Normally the SIPOC map is constructed horizontally. When mailing this deliverable to your instructor, it formats better vertically. TARGET ASSIGNMENT DATE - Submit in Week 4 or earlier Project: Healthcare Deliverable: SIPOC Student last name: Your LAST name here Suppliers: HINT! Lois Jordan: Suppliers provide things that are used during the process you outlined below. (At least 3) Inputs: HINT! Lois Jordan: Inputs are used during the process you outlined below. (At least 3) Process Step 1: Process Step 2: Process Step 3: Process Step 4: Process Step 5: Process Step 6: Process Step 7: Process Step 8: Outputs: HINT! Lois Jordan: Outputs are created by the process you outlined above. (At least 3) Customers: HINT! Lois Jordan: Customers receive the outputs created by the process you outlined above. Lois Jordan: Suppliers provide things that are used during the process you outlined below. Lois Jordan: Outputs are created by the process you outlined above. Lois Jordan: Inputs are used during the process you outlined below. (At least 3) How to submit an Assignment DO NOT SEND ANY EXTRA ATTACHMENTS UNLESS YOUR INSTRUCTOR SPECIFICALLY ASKS YOU TO!! Please hand-in your assignments throughout the course. DO NOT SAVE THEM FOR THE END. The deadline for having all project deliverables 100\% correct is 7 days prior to the end of the course. Measure (Baseline Sigma) Objective: We want you to determine the baseline sigma with the Motorola 1.5 sigma shift. Note: You will need to refer to the tab entitled The Project for this deliverable. Instructions for you: Calculate the PPM/DPMO for this process and determine the baseline sigma with the Motorola shift. Data: 6.3\% of people left without treatment TARGET ASSIGNMENT DATE - Submit in Week 7 or earlier Project: Healthcare Deliverable: Baseline Sigma Student last name: Your last name here What is the baseline sigma? (Approximately) (Use 1 decimal place) Check Lois Jordan: Your answer should be between 2 and 4.5 DO NOT SEND ANY EXTRA ATTACHMENTS UNLESS YOUR INSTRUCTOR SPECIFICALLY ASKS YOU TO!! Please hand-in your assignments throughout the course. DO NOT SAVE THEM FOR THE END. The deadline for having all project deliverables 100\% correct is 7 days prior to the end of the course. Analyze (Pareto Chart) Objective: You need to determine the biggest contributors to the problem. One tool to accomplish this is the Pareto Chart. Instructions for you: Using the data (blue) below construct a Pareto chart (see the online video lecture for more). We realize that you could simply pick the two or three process components without actually creating the Pareto Chart, but we want you to actually create the Pareto Chart because in reality management likes to see simple charts where they dont have to analyze the data to see the picture. That is why the Pareto Chart is used in the first place. SAMPLE Notice: The shaded section below has a practice problem intended to help you with this assignment. If you want to skip this hypothetical problem, you can. Hypothetical problem (This is NOT the project data which is why this is separated in a shaded box) Lets say that data reveals the following counts for help-desk occurrences for the month of July. Injury categories # of occurrences Cuts from broken glass 12 This green area is just for practice. Surf boarding injuries 37 The project data are below in blue. Fishing related injuries 41 Jelly fish stings 45 Skim boarding accidents 29 Hit with flying toy 79 Sprained ankle 43 Jet Ski accidents 34 Burns from grills 52 Misc. 22 The first thing you would have to do is sort the data from the largest count of injuries to the smallest. It would look like this after sorting. Then, you would create a cumulative percentage column. Click once on any of the cumulative percentages to see the formula. Injury categories # of occurrences Cumulative \% Hit with flying toy 79 20\% How did you get 20? daniel-munson: Instructor: Step 1. Click in the adjacent blank cell and enter an equal (=) sign. Step 2. Click on the cell with the 79. Step 3. Type in a division sign (/). Step 4. Click in the cell with the 394. Step 5. Click enter Burns from grills 52 33\% How did you get 33? daniel-munson: Instructor: Step 1. Click in the adjacent blank cell and enter an equal (=) sign. Step 2. Click on the cell with the 20\% in it. Step 3. Type + and a parenthesis sign Step 4. Click on the cell with the 52. Step 5. Type in a division sign (/). Step 6. Click in the cell with the 394. Step 7. Type a close parenthesis sign Step 8. Click enter Jelly fish stings 45 45\% Sprained ankle 43 56\% Fishing related injuries 41 66\% Surf boarding injuries 37 75\% Jet ski accidents 34 84\% Skim boarding accidents 29 91\% Misc. 22 97\% Cuts from broken glass 12 100\% 394 ..Back to the project itself... Data: Reasons for customer dissatisfaction: Total customers choosing this particular response Cumulative \% Got tired of waiting 6 Had to go / ran out of time 4 Too many people waiting 4 Doctor treatment 3 Staff treatment 2 Environment 2 Elsewhere 1 Ignored me 1 Too expensive 1 Not necessary 1 TOTAL 25 Create a Pareto chart in Excel 2003 or earlier Diane Johnson: Instructor: Instructions for creating a pareto chart in Excel 2003 or earlier 1. Create a table that looks like the practice problem (above), but with the project data (not the practice data). One column is the counts and the second column is the cumulative percentages. 2. Highlight both columns of data without the labels 3. Click INSERT on the top tab bar 4. Click Chart 5. Click Custom types (one of the tabs) 6. Choose Line - Column on 2 axes (scroll down to find it) 7. Finish to create the chart 8. Right click on left Y axis 9. Click on Format Axis 10. Click Scale 11. Change max to 25 and min to zero 12. OK 13. Right click on right Y axis 14. Click Scale 15. Change max to 1 and min to zero 16. OK 17. Now you have a pareto chart. The cumulative percentage line begins at the top of the first column and rises to 100\%. When your pareto chart follows this standard business format, it will enhance communication and presentations to management. If you would like to PRINT these instructions, right click on the cell and select EDIT COMMENTS. Then just highlight the text, copy and paste into a document to print. Create a Pareto chart in Excel 2007 or later Diane Johnson: Instructor: Excel 2007 or later 1. Create a table that looks like the practice problem (above), but with the project data (not the practice data). One column is the counts and the second column is the cumulative percentages. 2. Highlight both columns of data without the labels 3. Click INSERT on the ribbon. 4. Click Clustered Column Chart to insert the chart 5. Right click the columns that represent the percentages (smaller columns) 6. Click Format Data Series 7. Under series options, click Plot Series On Secondary Axis. 8. On the Layout tab, in the Axes group, you may modify the Secondary Vertical Axis. 9. Right click on the percentage columns, Select Change Series Chart type to LINE 10. Right click on left Y axis and click Format Axis 11. In the Bounds Section, change max to the total of all counts from all columns and a min to zero 12. Right click on right Y axis (secondary axis) and click Format Axis 13. In the Bounds Section, change max to 1.0 (100\%) and min to zero 14. Right click the columns for the defect categories, and click Select Data. 15. For series 1, click inside the box for Horizontal (Category) axis labels. 16. Select the labels for the defects in the table (the leftmost column) and click ok. 17. Right click the percentages line 18. Select add data labels to add data labels to the percentage line. 19. Now you have a pareto chart. The cumulative percentage line begins at the top of the first column and rises to 100\%. When your pareto follows this standard business format, it will enhance communication and presentations to management. If you would like to PRINT these instructions, just right click the cell, and choose EDIT COMMENT. Then, highlight the text, copy and paste into a document to print. daniel-munson: Instructor: Step 1. Click in the adjacent blank cell and enter an equal (=) sign. Step 2. Click on the cell with the 79. Step 3. Type in a division sign (/). Step 4. Click in the cell with the 394. Step 5. Click enter daniel-munson: Instructor: Step 1. Click in the adjacent blank cell and enter an equal (=) sign. Step 2. Click on the cell with the 20\% in it. Step 3. Type + and a parenthesis sign Step 4. Click on the cell with the 52. Step 5. Type in a division sign (/). Step 6. Click in the cell with the 394. Step 7. Type a close parenthesis sign Step 8. Click enter Diane Johnson: Instructor: Instructions for creating a pareto chart in Excel 2003 or earlier 1. Create a table that looks like the practice problem (above), but with the project data (not the practice data). One column is the counts and the second column is the cumulative percentages. 2. Highlight both columns of data without the labels 3. Click INSERT on the top tab bar 4. Click Chart 5. Click Custom types (one of the tabs) 6. Choose Line - Column on 2 axes (scroll down to find it) 7. Finish to create the chart 8. Right click on left Y axis 9. Click on Format Axis 10. Click Scale 11. Change max to 25 and min to zero 12. … DMAIC_Roadmap Lean Six Sigma DMAIC Roadmap Purpose Key Tools Key Outputs Define To establish a quantified problem statement, objective and business case that will become the foundation to your Six Sigma project. Conduct stakeholder analysis, select team members and kick-off your project. Primary Metric Process Map Project Charter Project Plan * Process Map * Gather VOC * Translate VOC to CTQs * QFD/HOQ * COPQ * Primary & Secondary Metrics * Establish Project Charter * Stakeholder Analysis * Team Selection * Project Plan Measure Refine your understanding of the process. Assess process capability relative to customer specifications. Validate measurement systems. Brainstorm potential xs. C&E SIPOC FMEA Cpk * Early Y=f(x) Hypothesis * Detailed Process Map * SIPOC * Cause & Effect Diagram * Cause & Effect Matrix * FMEA * Basic Statistics * Normality Test * Capability Analysis * Gage R&R Analyze Conduct data collection and planned studies in order to eliminate non-critical xs and validate critical xs. Establish a stronger and quantified Y=f(x) equation. Normality Test ANOVA 2 Sample t-test Equal Variances * Narrowed Y=f(x) * 1 & 2 Sample t-tests * 1 & 2 Proportions tests * Equal variance tests * Normality tests * ANOVA * Moods Median * Mann Whitney * Paired t-test * Chi-Squared test Improve Design, test and implement your new process or product under live operating conditions. Pilot solutions if feasible before broadly deploying expensive improvements or products. Pugh Matrix Linear Regression Binary Logistic Regression DOE * Refined Y=f(x) * Pugh Matrix * Correlation * Simple Linear Regression * Multiple Linear Regression * Binary Logistic Regression * Full Factorial DOE * Fractional Factorial DOE Control Plan, communicate, train and implement your product or process solutions. Ensure control mechanisms are established. Use Poke Yoke, visual controls, SOPs and SPC wherever possible. Control Plan SOPs Communication Plan SPC * Control Plan * Training Plan * Refined FMEA * Communication Plan * Standard Operating Procedures * Five-S Audit * Poke Yoke * Visual Controls * Statistical Process Control VILLANOVA UNIVERSITY DMAIC_Project_Checklist D.M.A.I.C Project Checklist DEFINE IMPROVE 2 Projecct Charter 2 Potential Solutions Developed 2 Business Case (why is this project important) 2 Potential Solutions Prioritized 3 Problem Statement & Objective 2 Solution Selected 2 Baseline Data (Primary Metric Y) 2 Improvement Pilot/Test Plan 2 Target 2 Improvement Pilot/Test Execution 2 COPQ Estimate 2 Improvement Verified 2 Project Team 2 New Process Capability 2 Project Scope 2 Updated Process Map 2 Project Timeline 2 Solution Implementation Plan 2 Project Constraints/Dependencies 2 Primary Metric Updated 2 High Level Process Map 2 COPQ Revision 2 Customer Requirements Identified 2 Improve Phase Report 2 Define Phase Report MEASURE CONTROL 2 Detailed Process Map 2 Full Solution Implementation 2 SIPOC 2 Standard Operating Procedures Developed 3 Data Collection Plan (Potential Xs) 2 Communication Plan 2 Measurement Systems Analysis (Primary Y) 2 Training Plan 2 Process Capability Analysis 2 Audit Plan 2 List of Possible Xs 2 Control Charts 2 Prioritized List of Xs to be Analyzed 2 Control Plan 2 Primary Metric Updated 2 Primary Metric Updated 2 COPQ Revision 2 COPQ Revision 2 Measure Phase Report 2 Full Project Report ANALYZE 2 Sources of Variation Identified 2 Potential Xs Eliminated 2 Root Causes Confirmed (Critical Xs Identified) 2 Primary Metric Updated 2 COPQ Revision 2 Analyze Phase Report VILLANOVA UNIVERSITY Contents Lean Six Sigma Toolkit Table of Contents Project Charter Six Sigma Process Map SIPOC VOC Affinity Diagram CTQ PARETO CHART TEMPLATE Data Collection Sheet DPMO Calculator DPMO Data STEM AND LEAF Solution Selection Matrix A3 Counter Measures Failure Modes and Effects Analysis Severity Definition Occurrence Definition Detection Definition Scorecard Gantt Chart Instructions Gantt Chart Control Plan RACI Cause and Effect Diagram Communication Plan Training Plan Audit Checklist Pugh Matrix C and E Matrix Risk Management Plan Sample Size Calculator Takt Time Calculator Z Distribution Table T Distribution Table F Distribution Table Chi Square Distribution Table PROCESS MAP TEMPLATE TREE DIAGRAM TEMPLATE CORRELATION COEFFICIENT HISTOGRAM (use EXCEL to Create BINs & HISTOGRAMS) USE EXCEL HELP for instructions on creating BINS and HISTOGRAMS based on version of EXCEL you are using. SEE SSGB120 TEXTBOOK Pp/Ppk SEE SSGB120 TEXTBOOK for Instruction & formula STEM AND LEAF SEE SSGB120 TEXTBOOK for Instruction MEASURES OF CENTRAL TENDENCY USE EXCEL HELP FOR FORMULA AND INSTRUCTIONS MEASURES OF DISPERSION USE EXCEL HELP FOR FORMULA AND INSTRUCTIONS PAIRED t TEST USE EXCEL HELP FOR FORMULA AND INSTRUCTIONS OR USE SSGB120 TEXTBOOK t TEST USE EXCEL HELP FOR FORMULA AND INSTRUCTIONS OR USE SSGB120 TEXTBOOK SCATTER PLOTT USE EXCEL Project_Charter Project Title: GO HOME!! Black Belt Project Champion Executive Sponsor MBB/Mentor Problem Statement Business Case Project Goals Project Scope Milestones Constraints & Dependencies Project Risks Any additional information Approval/Steering Committee Stakeholders & Advisors Project Team & SMEs Name Organization Name Organization Name Organization VILLANOVA UNIVERSITY Six Sigma Process Map SIX SIGMA PROCESS MAP TEMPLATE GO HOME!! PROCESS ANALYSIS COMPLETED BY DEPARTMENT(S) DATE COMPLETED K E Y COPY AND PASTE BLANK ICONS BELOW LEARN MORE ABOUT SMARTSHEET FOR PROJECT MANAGEMENT STEP START / END INPUT / OUTPUT DOCUMENT FLOWCHART LINK CONNECTORS https://goo.gl/wZizs0 SIPOC S.I.P.O.C. Template GO HOME!! Suppliers Inputs Process Outputs Customers VILLANOVA UNIVERSITY Start Step 1 Step 2 Step 3 Step 4 End Voice of Customer Six Sigma VOICE OF CUSTOMER (VOC) SIX SIGMA TEMPLATE GO HOME!! ID CUSTOMER IDENTITY VOICE OF THE CUSTOMER KEY CUSTOMER ISSUE(S) CRITICAL CUSTOMER REQUIREMENT # Who is the customer? What did the customer say? What does the customer need? What resulting action is required? 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LEARN MORE ABOUT SMARTSHEET FOR PROJECT MANAGEMENT https://goo.gl/p27jL8 Affinity Diagram GO HOME!! Affinity Diagram - Dr Deasley Staffing Issues High Turnover Frustrated Nurses Data Collection Plan Template DATA COLLECTION PLAN TEMPLATE GO HOME!! PROJECT NAME DATE PREPARED BY ID PERFORMANCE MEASURE OPERATIONAL DEFINITION DATA SOURCE & LOCATION SAMPLE SIZE WHO WILL COLLECT DATA? WHEN WILL DATA BE COLLECTED? HOW WILL DATA BE COLLECTED? HOW WILL DATA BE USED? ADDITIONAL DATA TO BE COLLECTED AT SAME TIME # 1 2 3 4 5 6 7 8 9 10 11 12 LEARN MORE ABOUT SMARTSHEET FOR PROJECT MANAGEMENT https://goo.gl/qdc7cy Stem and Leaf GO HOME!! Project: Dr Deasley Deliverable: Stem & Leaf Student last name: Your last name here 9 8 7 6 5 4 3 2 1 0 Is it reasonably normally distributed? If it is not normal, what shape is it? (Use the correct name for this shape, not a description.) Based on this analysis, what is the next thing you would do? Solution Selection Matrix Solution Selection Matrix GO HOME!! Project Goal Please rank each solution for each criteria by using the 1-5 Scale as indicated below Increase IISE SDD Membership Engagement by 10\% Very Low (less good) Moderate Very High (best) 1 2 3 4 5 Potential Solution (Provide Brief Description) Potential to Meet Goal Positive Customer Impact Cost to Implement (1 = $$$ & 5 = $) Stakeholder Buy-in Time to Implement (1 = Long 5 = Quick) Total Score Implement? Yes/No Weighted Criteria 10 9 8 7 5 IISE Sustainable Development Division Membership Engagement Coffee talks with Lean topics 5 3 2 4 5 146 Yes More interactive sessions, instead of standard panel discussions 5 4 4 3 1 144 Yes Board meetings, problem solving discussion groups 5 4 4 3 1 144 Yes Tracks for problem solving – interactive session less directive 5 4 4 3 1 144 Yes Could we utilize the app to gain feedback? 5 5 2 3 1 137 Yes IISE Connect? 5 4 5 5 5 186 Yes Discussions with TVPs and Track Chairs 2 3 2 3 1 89 Yes Can we do this outside of the conference? 4 4 3 3 2 131 Yes Survey – VOC 3 3 5 3 5 143 Yes &Arial,Bold&10Solution Selection Matrix &Arial,Regular&8v1.0 &Arial,Regular&8&G_x000D_Copyright 2017 GoLeanSixSigma.com. All Rights Reserved. A3 Project XYZ Location Date: Project Leader: Tina Agustiady Team Members GO HOME!! Project XYZ Strategic Project Critical Project X Issue Resolution 1. Project Goal 3. Action Plan Action Owner Due Date 2017 - Week Beginning Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov 5 12 19 26 2 9 16 23 30 6 13 20 27 6 13 20 27 3 10 17 24 1 8 15 22 29 5 12 19 26 3 10 17 24 31 7 14 21 28 4 11 18 25 2 9 16 23 30 6 13 20 27 2. Project/Problem Analysis (Project: Objectives; Problem: Root Cause, Barriers, Roadblocks) Out of scope items: 4. Results (Impact on Targets to Improve) For each line item determine \% completion Element Item \% complete sitewide Comment 0\% 0\% 0\% 0\% 0\% 0\% 0\% 0\% 0\% 0\% 0\% 0\% 5. Unresolved Issues - Risks: Legend Planned Timeline to Complete Action Planned Due Date Planned Action ON TARGET Planned Action OFF TARGET Planned Action Past Due Planned Action Complete CounterMeasureTemplate Countermeasure for Project Data Table Plant: # Reasons (Root Cause Short Description. This MUST come from a root cause analysis tool) Impact Month Enter KPI Target Savings Target Gap Closure Target Actual Better Worse GO HOME!! Date of Review: Enter Date of Review 1 Start Month: Enter 1st Month Counter Measure Form Is Used Jan 2 Feb Mar 3 Apr May 4 June July 5 Aug Sep 6 Oct Nov 7 Dec Problem Statement: 8 Enter Problem Statement 9 10 Overall Impact (Note: Should Exceed Gap to Close) 0.00\% # Reasons (Enter Reason Being Addressed from Above) What (Describe actions being taken to address this Root Cause) Who (Resp for action and impact) When (Date Complete) Impact (Target Benefit by the Complete Date) Status (P,D,C,A) Planned Impact Improvement (Note: This must equal or exceed the gap closure target) 0.00\% Enter Title Better Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec 0 0 0 0 0 0 0 0 0 0 0 0 Worse Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec 0 0 0 0 0 0 0 0 0 0 0 0 Target Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec Actual 0 0 0 0 0 0 0 0 0 0 0 0 Gap Closure PFMEA # Process Function (Step) Potential Failure Modes (process defects) Potential Failure Effects (KPOVs) SEV Class Potential Causes of Failure (KPIVs) OCC Current Process Controls DET RPN Recommend Actions Responsible Person & Target Date Taken Actions SEV OCC DET RPN GO HOME!! 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 30 0 30 0 31 0 32 33 34 35 Severity Effect Criteria: Severity of Effect Defined Ranking GO HOME!! Hazardous: Without Warning May endanger operator. Failure mode affects safe vehicle operation and / or involves noncompliance with government regulation. Failure will occur WITHOUT warning. 10 Hazardous: With Warning May endanger operator. Failure mode affects safe vehicle operation and / or involves noncompliance with government regulation. Failure will occur WITH warning. 9 Very High Major disruption to production line. 100\% of product may have to be scrapped. Vehicle / item inoperable, loss of primary function. Customer very dissatisfied. 8 High Minor disruption to production line. Product may have to be sorted and a portion (less than 100\%) scrapped. Vehicle operable, but at a reduced level of performance. Customer dissatisfied. 7 Moderate Minor disruption to production line. A portion (less than 100\%) may have to be scrapped (no sorting). Vehicle / item operable, but some comfort / convenience item(s) inoperable. Customers experience discomfort. 6 Low Minor disruption to production line. 100\% of product may have to be reworked. Vehicle / item operable, but some comfort / convenience item(s) operable at reduced level of performance. Customer experiences some dissatisfaction. 5 Very Low Minor disruption to production line. The product may have to be sorted and a portion (less than 100\%) reworked. Fit / finish / squeak / rattle item does not conform. Defect noticed by most customers. 4 Minor Minor disruption to production line. A portion (less than 100\%) of the product may have to be reworked on-line but out-of-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by average customers. 3 Very Minor Minor disruption to production line. A portion (less than 100\%) of the product may have to be reworked on-line but in-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by discriminating customers. 2 None No effect. 1 Occurrence Probability of Failure Possible Failure Rates Cpk Ranking GO HOME!! Very High: ³ 1 in 2 < 0.33 10 Failure is almost inevitable 1 in 3 ³ 0.33 9 High: Generally associated with processes similar to previous 1 in 8 ³ 0.51 8 processes that have often failed 1 in 20 ³ 0.67 7 Moderate: Generally associated with processes similar to 1 in 80 ³ 0.83 6 previous processes which have 1 in 400 ³ 1.00 5 experienced occasional failures, but not in major proportions 1 in 2,000 ³ 1.17 4 Low: Isolated failures associated with similar processes 1 in 15,000 ³ 1.33 3 Very Low: Only isolated failures associated with almost identical processes 1 in 150,000 ³ 1.5 2 Remote: Failure is unlikely. No failures ever associated with almost identical processes £ 1 in 1,500,000 ³ 1.67 1 Detection Detection Criteria: Liklihood the existence of a defect will be detected by test content before product advances to next or subsequent process Ranking GO HOME!! Almost Impossible Test content detects < 80 \% of failures 10 Very Remote Test content must detect 80 \% of failures 9 Remote Test content must detect 82.5 \% of failures 8 Very Low Test content must detect 85 \% of failures 7 Low Test content must detect 87.5 \% of failures 6 Moderate Test content must detect 90 \% of failures 5 Moderately High Test content must detect 92.5 \% of failures 4 High Test content must detect 95 \% of failures 3 Very High Test content must detect 97.5 \% of failures 2 Almost Certain Test content must detect 99.5 \% of failures 1 Scorecard Villanova Basic Scorecard GO HOME!! Calculate Status Q115 Q215 Q315 Q415 Full Year 2015 Current FYF Key Business Metrics Goal Fcst Actual Goal Fcst Actual Goal Fcst Actual Goal Fcst Actual Goal Fcst Actual 1.16 0.97 Operating Expense Reduction $15.0 $12.0 $8.0 $25.0 $25.0 $29.0 $35.0 $36.0 $25.0 $24.0 $100.0 $97.0 0.9672131148 ERROR:#DIV/0! Customer Satisfaction $61.0 $58.0 $57.0 $61.0 $58.0 $59.0 $61.0 $59.0 $59.0 $61.0 $61.0 ERROR:#DIV/0! ERROR:#DIV/0! Net Income 0 1.05 OWT $10.0 $10.0 $0.0 $10.0 $10.0 $13.1 $40.0 $40.0 $60.0 $63.0 Operating Metrics 3 3 Recall Open Cases 3 3 Recall Open Case Dollars 3 3 Recall Cases w/Purchasing 3 3 Recall Case Dollars w/Purchasing 3 3 Legacy Open Cases 3 3 Legacy Open Case Dollars 3 3 Legacy Cases w/Purchasing 3 3 Legacy Case Dollars w/Purchasing 1 1 OWT Cumulative Parts Reviewed 31,200 3,802 52,800 4,967 52,800 4,967 1 1 OWT Cumulative Recovery Groups w/TF 1,213 189 1,933 195 1,933 195 Status Rules: Current status based on forecast vs. goal for future periods and based on actual vs. goal for past period. FYF status based on full year forecast vs. Goal until the year completes. Status Conditions: Green >=100\% of Goal, Yellow 95\%-99\% of Goal, Red <95\% of Goal $dollars represented in Millions VILLANOVA UNIVERSITY Gantt Chart Instructions GO HOME!! Project Plan Guide: •To delete these instructions, select this text box and then hit [Delete]. Date Cells (H6:GU7) These cells power much of the conditional formatting and allow the project plan to float. All the cells are indirectly referenced to cell G6, which can be set to a firm date (ex. 2/1/2010) or a reference (ex. =MIN([project dates])). Adjusting cell G6 will shift the entire calendar. Task Cells (A10:F40) The tasks have three levels, deliverable, task and sub task. Each has a different conditional format in the Gantt chart area. Deliverable Sections The deliverable section(s) (ex. 15:19) can be copied and pasted as rows to add new deliverable sections below the existing sections if needed. Within each deliverable section you can add additional room for tasks by inserting a row above the light blue row (ex. 13). This way the appropriate conditional formatting is added and no formulas are compromised. Task s By entering a task in the B column the conditional formatting will make the associated bar a medium blue. By entering a task in the C column the associated bar will be light blue. The bar is shown via conditional formatting based on the dates entered (Cols D:E) cross referenced with the calendar across the top. Task dependence/precedence can be managed by creating formulas between the data cells instead of firm dates (ex. =E11+5 vs. 2/10/2010). Special Events (B2:E7) Functionality was added to allow for up to five special events that will highlight the background color. This was intended for non-task events that may need to be included. Misc. - There is a current date indicator that will show the current date on the Gantt chart. - The Gantt chart bars and the task list will highlight according to \% complete status. - The Page Setup includes repeating rows of 2:9 and repeating columns of A:G. To print a small section of the chart simply select the area of the Gantt chart (ex. H10:AZ41) and set it as the Print Area. - Hypothetically additional days can be added to the calendar by copy and inserting columns to the left of Column GU. Be sure to check that the formulas in 6:7 and 4:5 have been copied appropriately. Gantt Chart Special Events Start End Project Plan Template Time off 12/5 12/18 GO HOME!! Holiday 10/20 10/20 Sep Oct Nov Dec Jan Feb Mar 9/6 9/7 9/8 9/9 9/10 9/11 9/12 9/13 9/14 9/15 9/16 9/17 9/18 9/19 9/20 9/21 9/22 9/23 9/24 9/25 9/26 9/27 9/28 9/29 9/30 10/1 10/2 10/3 10/4 10/5 10/6 10/7 10/8 10/9 10/10 10/11 10/12 10/13 10/14 10/15 10/16 10/17 10/18 10/19 10/20 10/21 10/22 10/23 10/24 10/25 10/26 10/27 10/28 10/29 10/30 10/31 11/1 11/2 11/3 11/4 11/5 11/6 11/7 11/8 11/9 11/10 11/11 11/12 11/13 11/14 11/15 11/16 11/17 11/18 11/19 11/20 11/21 11/22 11/23 11/24 11/25 11/26 11/27 11/28 11/29 11/30 12/1 12/2 12/3 12/4 12/5 12/6 12/7 12/8 12/9 12/10 12/11 12/12 12/13 12/14 12/15 12/16 12/17 12/18 12/19 12/20 12/21 12/22 12/23 12/24 12/25 12/26 12/27 12/28 12/29 12/30 12/31 1/1 1/2 1/3 1/4 1/5 1/6 1/7 1/8 1/9 1/10 1/11 1/12 1/13 1/14 1/15 1/16 1/17 1/18 1/19 1/20 1/21 1/22 1/23 1/24 1/25 1/26 1/27 1/28 1/29 1/30 1/31 2/1 2/2 2/3 2/4 2/5 2/6 2/7 2/8 2/9 2/10 2/11 2/12 2/13 2/14 2/15 2/16 2/17 2/18 2/19 2/20 2/21 2/22 2/23 2/24 2/25 2/26 2/27 2/28 3/1 3/2 3/3 3/4 3/5 3/6 3/7 3/8 3/9 3/10 3/11 3/12 3/13 3/14 3/15 3/16 3/17 3/18 3/19 3/20 Start End \% Complete Project Deliverable 1 9/26 10/9 Task 1 9/26 10/9 80\% …