Black Belt Project Storyboard Template Visit Go Lean

Black Belt Project Storyboard Template Visit Go. Lean. Six. Sigma. com for more Lean Six Sigma Resources

Storyboard: The 5 Tenets 1. Tell Your Story – Make sure the flow is logical and the pictures do most of the work – make it clear to the reader what you learned at each step 2. Use the Tools – Show that you understand the DMAIC method and made good use of the tools and templates available to you 3. Label Your Graphs – List the metric name, the time frame and the takeaways for each chart 4. Show the Improvement – Make accomplishments clear – list each waste reduction, savings, revenue increase, cycle time reduction and customer satisfaction 5. Use the Appendix – Save back-up documentation, reference material and any extra graphs and tools in case readers would like more information

Executive Summary Questions & Activities to Address: • Use the Executive Summary template – Business Case: List the Business Case or Problem Statement from the Project Charter – Goal: List the Goal Statement from the Project Charter – Finding Highlights: List a bulleted list of Quick Wins, discoveries and other improvements that resulted from the project – Results: List the project savings, gains, cost avoidance, cycle time reduction, customer satisfaction, etc.

Key Words • List all words and acronyms that are specific to your industry and key to understanding your project • Provide a brief description or definition of each term • List in alphabetical order • Keep in mind that this document will be viewed by those who are not in your industry or familiar with your process or industry

Define Phase Questions & Activities to Address: • • • How and why the project was selected? Who was the customer and what did they require? Was the process data or process driven? What kind of map did you use (Swimlane, Value Stream, etc. ) Did you complete an 8 Wastes assessment of the process? Did you complete a 5 S Assessment (or in the Improve Phase)?

Potential Define Visuals • • Project Charter or A 3 SIPOC Swimlane Process Map, Value Stream Map, other VOC Translation Matrix Primary Metric Chart (Baseline data if available) 8 Wastes Checksheet 5 S Transactional Assessment 5 S Manufacturing Assessment

Define Phase Tollgate q Verify the project has a Champion/Sponsor and leadership backing q Get approval from a finance partner for the potential savings or projected revenue q Complete the elements of the Project Charter q Collect the Voice of the Customer and uncover any unknown requirements q Make customer requirements measurable q Create a high-level map of the process q Facilitate a team a Process Walk q Develop and verify a detailed map of the process q Conduct Stakeholder Analysis and develop an influence and communication plan

Measure Phase Questions & Activities to Address: • What was the approach to Data Collection? (Who measured, when, for how long? ) • What was the approach taken to validate that data collection method produces accurate results? (Measurement Systems Analysis? ) • What is the understanding of the process baseline(s) measures and what is the gap between the baseline and the goal? • What were the results of the Process Walk? • What is the understanding of the potential issues?

Potential Measure Visuals • • • Data Collection Plan Operational Definitions Efficiency and Effectiveness Matrix Sample Data Collection Sheet – Checksheet used Results of Measurement Systems Analysis (MSA, Gage R&R) • Graphic Display of Baseline Data - Time Series Plots, Control Charts, Box Plots, Histograms, etc. • “Before” Work Area Layouts – Photos, diagrams, Spaghetti Charts – Include distance travelled and time involved • Cost Of Poor Quality (COPQ) Calculations • Threats & Opportunities Matrix

Measure Phase Tollgate q Select Baseline Measurements q Develop a Data Collection Plan with Operational Definitions, stratification factors and checksheets if needed q Develop a Sampling Plan and calculate data needs q Conduct measurement systems analysis q Collect Baseline Data q Determine Process Capability q Update Project Charter and inform Stakeholders

Analyze Questions & Activities to Address: • What was the approach to process and data analysis along with key insights? • Provide the list of prioritized root causes (critical Xs and their impact on Y or primary metric) • What are the Hypothesis Statements – Null and Alternative? • What were the results of Hypothesis Testing? • Were there any Quick Wins and if so what were the results?

Potential Analyze Visuals • • Fishbone Diagram Value Cycle Time Analysis – wait time vs. work time Value Stream Map Hypothesis Testing Plan Root Cause Hypothesis Worksheet Hypothesis Test Results Graphs that show relationships or findings (e. g. Box Plots, Pareto Charts, Histograms, Time Series Plots, Control Charts, etc. )

Analyze Tollgate Checklist q Conduct Value and Cycle Time Analysis of the process to identify opportunities to reduce waste q Identify root causes using data analysis, process maps, Five Whys and Fishbone Diagrams q Develop a Root Cause Hypothesis and formal hypothesis statements q Collect data to run statistical tests and prove or disprove Root Cause Hypotheses q Check if the team has enough confidence in the analysis to move to the Improve Phase q Update the Project Charter and inform Stakeholders

Improve Questions & Activities to Address: • Provide a list of improvements made and to-be made • Describe the approach to prioritizing and selecting solutions that eliminated root causes – Barriers and efforts to overcome them – Mistake-proofing and other risk management methods employed – Pilot results and changes made to solutions • Describe the Implementation Plan and results

Potential Improve Visuals • • • 5 S Transactional Assessment 5 S Manufacturing Assessment Impact Effort Matrix Weighted Criteria Matrix Final Workplace Layout (updated Spaghetti Chart) Cross Training Matrix Training Plan Pilot Plan FMEA Implementation Plan Graphic display of change to Primary Metric (before and after) Future State Map

Improve Tollgate Checklist q Use team brainstorming to generate solutions to address the root cause q Run a pilot of the solutions if needed q Create a Design of Experiments where appropriate q Assess and mitigate risk of process changes q Implement solutions to address root cause q Confirm that implemented solutions sufficiently affect the output Y q Celebrate with the team and recognize them for their efforts

Control Questions & Activities to Address: • How the project will be monitored and what are the Response Plans? – Who is doing the monitoring, how often and how – Are the Trigger Measures based on Control Charts? – Will there be ongoing 5 S inspections? • • Describe the Control Plan that ensures the gains are maintained over the long term What documentation and standardization has been completed regarding the improved process? What visual management techniques will ensure adoption of process changes? (include pictures where appropriate) How will you demonstrate improved process performance over baseline? – Control Charts, other • • How has the Process Owner been prepared for hand-off and what is the Communication Plan? What were the lessons learned?

Potential Control Visuals • • Monitoring Plan Response Plan Control Chart and/or other graphical tacking methods New Procedure Audit Communication Plan Innovation Transfer Opportunities Executive Summary

Control Tollgate Checklist q Create a system and/or process to monitor results q Utilize Control Charts for ongoing monitoring of the output and key leading indicators q Finalize visual management of the process q Create Response Plans in case there is a drop in performance q Complete the Storyboard of the project q Assess innovation transfer opportunities q Hand over formal ownership to the process owner

Appendix In the appendix, include any supporting documentation, process maps and data charts that you may use in your panel review to respond to questions or provide evidence of tool applications. Visit Go. Lean. Six. Sigma. com for more Lean Six Sigma Resources