6 DMAIC Roadmap Define Project Charter Customer Requirements

σ 6 DMAIC Roadmap - Define Project Charter Customer Requirements Stakeholder Analysis • • • • The Business Case Problem Statement Goal Statement Project Scope Project Ys Roles Milestones Identify Customers Identify Their Requirements Create a 5 -Up Chart • Molecule Map Stakeholder Matrix Message Analysis Sheet Communication Plan Map the As-Is Process • SIPOC • Flow Chart • Value Stream Map • Cross Functional Map • Spaghetti Map • Do VA/NVA Analysis c 2007 All rights reserved Genesis Group

σ 6 DMAIC Roadmap - Measure Complete VSM Data Boxes • • Identify Key Data Gather Data Complete VA/NVA Analysis Create a Muda Matrix c 2007 All rights reserved Genesis Group 2

σ 6 DMAIC Roadmap - Measure Identify Potential Drivers of As-Is Process Performance • • • Cause/Effect Analysis Process Driver Matrix Analysis Kepner- Tregnoe Worksheet c 2007 All rights reserved Genesis Group Identify Quick Hits • • • Select Opportunities To Pursue Action Plan Take Action 3

σ 6 DMAIC Roadmap - Measure Review Existing Data • • ID Usable Data Transform Data Plan Data Collection • • Develop: • Operational Definitions • Sampling Plan • Collection Tools Assign Collection Responsibilities c 2007 All rights reserved Genesis Group Perform MSA • Determine: • • Resolution • Accuracy • Precision Adjust Data Collection Plan As Necessary 4

σ 6 DMAIC Roadmap - Measure Collect Data Display Data • Establish Baseline Levels of Performance • Determine Process Capability • • • Histogram Run Chart Pareto Chart Bar Chart Box Plot Multi-Vari Chart Establish The Gross Financial Opportunity • Complete Worksheet Revise Charter As Necessary Review: • Goals • Project Ys • Project Scope • The Timeline c 2007 All rights reserved Genesis Group 5

σ 6 DMAIC Roadmap - Analyze Verify Drivers of As-Is Process Performance • • Select/Prioritize Issues to Address Kepner- Tregoe Analysis Graphical Analysis Data Stratification Parameter Estimation Hypothesis Testing ANOVA Regression Analysis Takt time and Line Balance c 2007 All rights reserved Genesis Group 6

σ 6 DMAIC Roadmap - Improve Benchmarking • • Identify Opportunities Collect/analyze Data Develop High Level To-Be Process Design Develop Detailed To-Be Process Design • • • QFD Functional Analysis Process Analysis How-How Fishbones Moments of Truth c 2007 All rights reserved Genesis Group Single Piece Flow Pull Systems Work Cells Poka Yoke SMED Kaizen 5 S 7

σ 6 DMAIC Roadmap - Improve Perform a Gap Analysis • • • FMEA Stakeholder Analysis Communication Plan Develop the Implementation Plan • • Gantt Chart Force Field Analysis c 2007 All rights reserved Genesis Group Perform Cost/Benefit Analysis • Complete Worksheet

σ 6 DMAIC Roadmap - Improve Pilot the Implementation Plan • Prepare: • Procedures • Training • Data Collection Plan • Revise as Needed Begin Transfer of the To-Be Process to Its Owner • • Timeline Contract c 2007 All rights reserved Genesis Group 9

σ 6 DMAIC Roadmap - Control Establish Document New Control Plan Procedures • Identify Key Metrics • Validations • Complete Template • Establish Measurement Plan • Develop Visual Controls • Implement SPC c 2007 All rights reserved Genesis Group Train Process Participants • • Prepare Material Meetings Training Sessions Job Aids 10

σ 6 DMAIC Roadmap - Control Align Related Processes • • • Communication Links Data Flows Work Flow Close Project • Document Key Project: - Actions - Data - Lessons Learned - Possible Future Projects/Kiazens c 2007 All rights reserved Genesis Group 11