Advance Innovation Group Project Name Project Owner Project

Advance Innovation Group Project Name: Project Owner:

Project Progress Tracking OVERVIEW Define Measure Analyze Improve Control Tollgates: 10/June/2010 Planned XXXXXX Completed Steps: 11/March/2010 mm/dd/yyyy 15/March/2010 mm/dd/yyyy D 1. Map Project M 1. CTQ Characteristics& Standards A 1. Baseline Process I 1. Screen for Vital Xs C 1. MSA on Xs D 2. Approve Project M 2. Measurement System Analysis M 3. Data Collection A 2. Performance Objective A 3. Identify Drivers of Variation I 2. Screen for vital Xs I 3. Define Improved Process C 2. Improved Process Capability C 3. Establish Control Plan • QFD / CTQ Tree • Operational definition, • Baseline of Current Process • • • Key Deliverables: • List of Customer(s) and Project • • Tools: n n n n CTQs Team Charter High Level Process Map (COPIS) CAP Plan (Optional) Preliminary CBA, if applicable Survey Focus Groups Interviews ARMI, Stakeholder Analysis In/Out of Frame Threat vs. Opportunity Matrix Other _______ Specification limits, target, defect definition for Project Y(s) • Data Collection Plan • Measurement System Analysis n n n Data Collection Plan Continuous Gage R&R Attribute Gage R&R Sample Size Calculator Other _______ Performance • Normality Test • Statistical Goal Statement for Project • List of Statistically Significant Xs n n n n Basic Statistics Histogram Dot Plots Box and Whisker Plots Run Charts Normality Testing Continuous/Discrete Zst, Zlt Benchmarking Detailed Process Mapping Moments of Truth Nature of Work Flow of Work Fishbone Hypothesis Testing Regression Analysis Other _______ List of Vital Few Xs Transfer Function(s) Optimal Settings for Xs Confirmation Runs/Results Tolerances on Vital Few Xs n n n DOE Pugh Matrix New Process Mapping FMEA on new process Process Modeling / Simulation Other _______ • MSA Results on Xs • Post Improvement Capability • Statistical Confirmation of Improvements • Process Control Plan • Process Owner Signoff • Final CBA, if applicable n n n n Continuous Gauge R&R Discrete Gauge R&R Control Charts Hypothesis Testing CAP Plan Control Plan Other _______

Define Deliverables DEFINE Project Mapping and Pre DMAIC Analysis Project Charter Terms & Acronyms Used ARMI/RASIC Communication Plan Process Map (Flow Chart) SIPOC/COPIS

Project Mapping DEFINE Customer Sample Comments Key Output Characteristics Important to Customer (CTQ's)

DEFINE Graphical Summary

DEFINE Business Case Problem Statement Goal Statement In Scope Out Scope Project Charter

Milestones DEFINE Week 21 30 -Dec Week 20 23 -Dec Week 19 16 -Dec Week 18 2 -Dec 9 -Dec Week 17 Week 16 25 -Nov Week 15 Month 5 18 -Nov Week 14 4 -Nov 11 -Nov Week 13 Week 12 28 -Oct Week 11 Month 4 21 -Oct Week 10 7 -Oct 14 -Oct Week 9 Week 8 30 -Sep Week 7 Month 3 23 -Sep Week 6 16 -Sep Week 5 2 -Sep 9 -Sep Week 4 Week 3 Month 2 26 -Aug Dates 19 -Aug 13 -Aug Weeks Week 2 Month 1 Week 1 Months Define Measure Analyze Improve Control M 1 M 3 M 5 Close Define Phase Close Analyze Phase Milestone Reviews M 2 Close Measure Phase M 4 Close Improve Phase Close Control Phase

DEFINE Indicators Terms & Acronyms Used Definition

ARMI DEFINE Key Stakeholders Define Measure When Populating the Stakeholder, consider the ARMI: • A= Approver of team decisions • R= Resource or subject matter expert (ad hoc) • M= Member of team • I= Interested Party who will need to be kept informed Analyze Improve Control

RASIC DEFINE Activities Collect VOC from all stakeholders Conduct Stakeholder analysis Collect data for the last 12 months Analysis of data Report out on the Pre DMAIC Analysis Create Project Charter Send Charter for Executive Approval Approve Charter Build SIPOC Build Process Map Build the data collection plan Get the DCP Approved Approve DCP Collect Data Validate data Publish next steps to stakeholder • • • Responsible (R) : Approve (A) : Support (S) : Inform (I) : Consult (C) : Team Members RASIC Chart for Define & Measure Pre- DMAIC DEFINE MEASURE Solely and directly responsible for the activity (Owner) - Includes approving authority (A) Reviews and assures that the activity is being done as per expectations Provides the necessary help and support to the owner Is to be kept informed of the status/progress being made Is to be consulted for this activity for inputs

Communication Plan DEFINE Message Audience Media Who When

DEFINE Process Map

COPIS DEFINE Customer Output Process Input Supplier

Measure Deliverables MEASURE Data Collection Plan Measurement System Analysis Process Capability

Data Collection Plan MEASURE Y Operational Definition Defect Definition Performance Standard Specification Limit Opportunity Mode of Collecting Data Y Data Items Needed Data Type Unit of Decimal Places Measurement Database Container Formula to be Equipment Used for Measurement Calibration Info If new, when Planned Start Existing/New would the date for Database database be Collection ready Responsibility Training Need Operator Information

Measurement System Analysis MEASURE Minitab Descriptive Statistics Rule Description Acceptable A R&R % of Tolerance < 10% B % Contribution (R&R Std deviation) Smaller than Part to Part Variation C Number of distinct categories >=4 Overall Gage Result

MEASURE Process Capability

Analyze Deliverables ANALYZE Identify Potential Factors Fishbone DCP for Potential Factors Basic Analysis for Project Y Checking for Impact of Factors on Y Hypothesis Summary MSA results of Impacting Factors

ANALYZE Cause & Effect Diagram

DCP for Potential Xs ANALYZE Outlining Data Collection Steps for Xs Potential Cause Type of Data Collection Method Test to be Used Visualization plot Used

Basic Data Analysis for Project Y ANALYZE Randomness & Shape Study Randomness Study Normality Study

Basic Data Analysis for Project Y ANALYZE Spread & Central Tendency Study Spread Study Central Tendency Study

Checking for Impact of x 1 on Y ANALYZE Statistical Interpretation of Relationship Graphical Depiction Inference: Hypothesis Result

Checking for Impact of x 2 on Y ANALYZE Statistical Interpretation of Relationship Graphical Depiction Inference: Hypothesis Result

Checking for Impact of x 3 on Y ANALYZE Statistical Interpretation of Relationship Graphical Depiction Inference: Hypothesis Result

Checking for Impact of x 4 on Y ANALYZE Statistical Interpretation of Relationship Graphical Depiction Inference: Hypothesis Result

Checking for Impact of x 5 on Y ANALYZE Statistical Interpretation of Relationship Graphical Depiction Inference: Hypothesis Result

Hypothesis Summary ANALYZE Summary of Impacting Factors S. No. Factor p – Value Graphical Tool Used Inference Next Steps

MSA Results of Impacting Factors ANALYZE Checking the validity of data of the Impacting Factors S. No. Factor MSA Method Used MSA Result RCA for Problems Next Steps

Improve Deliverables IMPROVE Screening of the Impacting Factors Action Plan for Improving the Factors Basic Analysis of Improved Y Pre–Post Analysis of Project Y Pre-Post Analysis of Factor(s) Improve Summary – Take Aways

IMPROVE Screening of Impacting Factors Prioritize the Impacting Factors

Action Plan for Improving the Factors IMPROVE S. No. Pain Area Root Cause Improvement Idea Implementation Owner Implementation Status

Basic Data Analysis of Improved Y IMPROVE Randomness & Shape Study Randomness Study Normality Study

Basic Data Analysis of Improved Y IMPROVE Spread & Central Tendency Study Spread Study Central Tendency Study

Goal Validation of Y IMPROVE Statistical Validation of Improvement Graphical Depiction Inference: Hypothesis Result

Pre – Post Analysis of Project Y IMPROVE Statistical Validation of Improvement Hypothesis Result Graphical Depiction Optional Inference:

Pre – Post Analysis of Factor IMPROVE Statistical Validation of Improvement Hypothesis Result Graphical Depiction Optional Inference:

Pre – Post Analysis of Factor IMPROVE Statistical Validation of Improvement Hypothesis Result Graphical Depiction Optional Inference:

Pre – Post Analysis of Factor IMPROVE Statistical Validation of Improvement Hypothesis Result Graphical Depiction Optional Inference:

Pre – Post Analysis of Factor IMPROVE Statistical Validation of Improvement Hypothesis Result Graphical Depiction Optional Inference:

Pre – Post Analysis of Factor IMPROVE Statistical Validation of Improvement Hypothesis Result Graphical Depiction Optional Inference:

IMPROVE Improve Summary – Take Away

Control Deliverables CONTROL Control Plan & FMEA on Control Plan Time Series Study of Y – Pre & Post Control Charts & Inference for Y – Pre & Post Basic Analysis of Improved Y Establish Process Capability Control Charts & Inference (for X 1, X 2, X 3…) Cost Benefit Analysis and Sign Off

Control Plan & FMEA on Control Plan CONTROL What’s Controlled Goal/Spec Limits Control Method Who/What Measures Where Recorded Decision Rule / Corrective Action SOP

CONTROL Time Series Study of Y – Pre & Post Need Based

CONTROL Control Charts & Inference for Y – Pre & Post

Basic Data Analysis of Controlled Y CONTROL Randomness & Shape Study Randomness Study Normality Study

Basic Data Analysis of Controlled Y CONTROL Spread & Central Tendency Study Spread Study Central Tendency Study

Establish Process Capability CONTROL Process Capability – Post Implementation Z Bench (Long Term Sigma) Short Term Sigma (Long Term Sigma + 1. 5)

CONTROL Control Charts & Inference (x 1)

CONTROL Control Charts & Inference (x 2)

Cost Benefit Analysis & Sign Off CONTROL Benefit Source Cost Reduction Enhanced Revenues Labor Reduction Decreased Overhead COPQ Reduction Unit Benefit Units Impacted Total Benefit

APPENDIX

Stakeholder Analysis Want to see More Of Want to see Less Of Need Based

Advance Innovation Group www. advanceinnovationgroup. com E-26, Sector 8 Noida, UP – 201301 India Advance Innovation Group 3 continents. One team. AIG is headquartered in Boston, Massachusetts and maintains several consulting and training delivery centers across Asia Pacific including India. Asia Pacific operations is headquartered at Noida, India with several offices and training facilities. Global offices allow us closer client contact to better serve your needs, while enriching our services with global perspective and experience.