Professional Documents
Culture Documents
<Project Title
(State From ... To)>
< Last Name, First Name >
DefineMeasure
AnalyzeImproveControl
Wave No: <xx>
Review Date: <xx/xx/xxxx>
LEAN
SIX SIGMA
Program Nam
Lean Six Sigm
DefineMeasure
AnalyzeImproveControl
LEAN
SIX SIGMA
Control
Control Phase Road Map
Define Measure Analyze Improve Control
Activities Tools
• Implement Mistake Proofing • Mistake-Proofing/
Zero Defects
• Develop SOP’s, Training Plan & Process
Controls • Standard Operating Procedures
(SOP’s)
• ImplementSolution and Ongoing
Process Measurements • Process Control Plans
• Identify
Project Replication • Visual Process Control Tools
Opportunities • Statistical Process Controls
• Complete Control Gate (SPC)
• Transition Project to Process Owner • Solution Replication
• Project Transition Model
• Team Feedback Session
Bonacorsi Consulting 3
Control
Improve Summary
90 1
80
Average
80 3.0SL=75.30 2
70
70
60
50
X=59.80 60
50
15 pass pass pass pass pass Y Y
40 -3.0SL=44.30
30
20
40
30
20
16 fail fail fail pass fail N N
10
0 part 1 2 3 4 17 fail fail fail fail fail Y Y
R Chart by operator Response By operator
80 1 2 100 18 fail fail fail fail fail Y Y
Sample Range
70 90
60
50
3.0SL=56.83 80
70 19 pass pass pass pass pass Y Y
40 60
30
20
R=26.87
50
40 20 fail fail fail fail fail Y Y
10 30
0
0
-3.0SL=0.00E+00 20
10
Oper 1 2
"REPEATABILITY" -> 100.00% 80.00%
Components of Variation
100
Response By part "ACCURACY" -> 85.00% 70.00%
100
%Total Var 90
%Study Var 80
Percent
70
50
60
50
40
"OVERALL REPEATABILITY & REPRODUCIBILITY" -> 65.00%
"OVERALL REPEATABILITY, REPRODUCIBILITY & ACCURACY" -> 55.00%
30
20
0 10
Gage R&R Repeat Reprod Part-to-Part part 1 2 3 4
What is the observed capability
0.05 after improvement?
P=0.03817
<Right Click, and select Add Text>
Is the new improved process
stable & Capable & in control?
0.00 -3.0SL=0.00E+00
<Right Click, and select Add Text>
0 50 100 150
Sample Number
Bonacorsi Consulting 6
Descriptive Statistics / Process Control
Capability
Process Capability Analysis for Cholesterol
Process Data
Data
USL
USL 220.000
220.000 ST
* LT Target *
*
(Baseline)
193.133 LSL *
30
26.0455
22.4931
Mean 193.133
Sample N 30
Capability
*
0.34
StDev (ST) 26.0455
*
0.34
StDev (LT) 22.4931
*
120 140 160 180 200 220 240 260
apability Observed Perf ormance Expected ST Perf ormance Expected LT Perf ormance
Process Capability Analysis for Control Process Data
*
0.40
PPM < LSL
PPM > USL
* PPM
133333.33
< LSL
PPM > USL
*
151146.50
PPM < LSL
PPM > USL
*
116152.65 Potential (ST) Capability
* PPM Total 133333.33 PPM Total 151146.50 PPM Total 116152.65 USL 220.000
0.40 USL Cp *
ess Data Target *
220.000 ST
CPU 0.34
* LT
LSL *
*(Improved) CPL *
184.967
30
Mean 184.967
) 20.4206 Cpk
Sample N 0.34
30
) 16.3662
Cpm
StDev (ST) 20.4206 *
(ST) Capability
* StDev (LT) 16.3662
0.57
*
0.57 Overall (LT) Capability
*
140 160 180 200 220 240
Potential (ST) Capability *
Pp
LT) Capability
*
0.71
Observed Perf ormance
PPM < LSL
PPM > USL
*
0.00
Enter Key Slide Take Away (Key
Expected ST Perf ormance
PPM < LSL
PPM > USL
*
43119.06
Expected LT Perf ormance
PPM < LSL
PPM > USL
*
16153.51
Point)CpHere
PPU *
0.40
* PPM Total 0.00 PPM Total 43119.06 PPM Total 16153.51 CPU
PPL 0.57 *
0.71
CPL
Ppk *
0.40
Bonacorsi Consulting 7
Control
Takt Board - Monitor
TAKT BOARD: <Department Name>
Last Week: <CTQ>
This Week: <CTQ>
Day Scheduled Actual Diff (+/) Comments
Bonacorsi Consulting 8
Mistake Proofing (Poke Control
Yoke)
Bonacorsi Consulting 9
Control
FMEA
Risk Analysis recommended actions (Key Speaking Points)
Rating Index
Total Current RPN Risk
Bonacorsi Consulting 10
Control
RACI Chart
R
A== Responsible
Accountable –– The
The person
person who
who performs the action/task.
is held accountable that the action/task is
completed.
C = Consulted – The person(s) who is consulted before performing the
action/task.
I = Informed – The person(s) who is informed after performing the action/task.
Responsibl Accountabl
Step Action/Task e e Consulted Informed
1
2
3
4
5
6
7
8
9
10
Bonacorsi Consulting 12
Control / Response & Escalation Control
Plan
Process Escalation Plan
Process Escalation Map
Type 2: Describe the chain of causality that shows how you determined the Type 2 savings. (tell
the story with cause–effect relationships, on how the proposed change should create the
desired financial result (savings) in your project )
Show the financial calculation savings and assumptions used.
Assumption #1 (i.e. Labor rate used, period of time, etc…)
Assumption #2 (i.e. contractor hrs or FTE, source of data, etc…)
Describe the Type 3 Business Impact(s) areas and how these were measured
Assumption #1 (i.e. project is driven by the Business strategy?)
Assumption #2 (i.e. Customer service rating, employee moral, etc…)
Other Questions
Stakeholders agree on the project’s impact and how it will be measured in financial terms?
What steps were taken to ensure the integrity & accuracy of the data?
Has the project tracking worksheet been updated?
Bonacorsi Consulting 16
Control
Next Steps
Key actions
Planned Lean Six Sigma Tool use
Questions to answer
Barrier/risk mitigation activities
Lean Six Sigma Project Issue Log
Last Revised:
Status Revised Due
No. Description/Recommendation Due Date Resp Comments / Resolution
Open/Closed/Hold Date
1
2
3
4
5
6
7
8
9
10
d
9%
ct plet
0% rd s
00 at s
ize
(7 nda tion
(1 plic tion
% ed
pr com
Replication Strategy
sta oca
Re oca
)
oje
)
1 st
l
Build change team 5
9
Train / Kaizen
Enter Key Slide Take Away (Key Point) Here
Bonacorsi Dashboard Metrics
Consulting 18
Control
Lessons Learned
1. ?
2. ?
3. ?
4. ?
5. ?
6. ?
7. ?
8. ?
9. ?
10.?
Bonacorsi Consulting 19
Control
Project Contributors
Steering Team Support Team
<Name>: <Contribution>
<Name>: <Contribution>
<Name>: <Contribution>
<Name>: <Contribution>
<Name>: <Contribution>
<Name>: <Contribution>
<Name>: <Contribution>
<Name>: <Contribution>
<Name>: <Contribution>
<Name>: <Contribution>
Project Ownership Team Deployment Team
<Name>: <Contribution> <Name>: <Contribution>
<Name>: <Contribution> <Name>: <Contribution>
<Name>: <Contribution> <Name>: <Contribution>
<Name>: <Contribution> <Name>: <Contribution>
<Name>: <Contribution> <Name>: <Contribution>
Bonacorsi Consulting 21
Control
Control Tollgate Checklist
❑ Has the team prepared all the essential documentation for the improved Key Deliverables
process, including revised/new Standard Operating Procedures (SOP’s), a
training plan and a process control system? ❏ SOP’s
❑ Has the necessary training for process owners/operators been performed
❏ Training Plan
❑ Have the right measures been selected, and documented as part of the
Process Control System, to monitor performance of the process and the ❏ Process Control System
continued effectiveness of the solution? Has the metrics briefing
plan/schedule been documented? Who owns the measures? Has the ❏ Financial Benefit Analysis
Process Owner’s job description been updated to reflect the new ❏ Validated Solution
responsibilities? What happens if minimum performance is not achieved?
❑ Has the solution been effectively implemented? Has the team compiled ❏ Replication/Standardization Plan
results data confirming that the solution has achieved the goals defined in ❏ lessons Learned
the Project Charter?
❑ Have the Financial Benefit Worksheets been documented? Has the ❏ Project Risk Performance
financial controller reviewed?
❏ Completed Steering Team Review
❑ Has the process been transitioned to the Process Owner, to take over
responsibility for managing continuing operations? Do they concur with ❏ Project Tracker Updated
the control plan?
❏ Transition Plan to Process Owners
❑ Has a final Storyboard documenting the project work been developed?
❑ Has the team forwarded other issues / opportunities, which were not able
to be addressed, to senior management?
❑ Have “lessons learned”been captured?
❑ Have replication opportunities been identified and communicated?
Bonacorsi Consulting 23