u Lean Six Sigma Define Phase Tollgate Review

u Lean Six Sigma Define Phase Tollgate Review Define Phase

Lean Six Sigma DMAIC Tools and Activities u Review Project Charter u Validate High-Level Value u Value Stream Map Flow u Identify Key Input, Process u Identify Root Causes u Reduce List of Potential Root u Develop Potential Solutions u Evaluate, Select, and u Develop SOP’s, Training Plan Stream Map and Scope u Validate Voice of the Customer & Voice of the Business u Validate Problem Statement and Goals u Validate Financial Benefits u Create Communication Plan u Select and Launch Team u Develop Project Schedule u Complete Define Tollgate and Output Metrics u Develop Operational Definitions u Develop Data Collection Plan u Validate Measurement System u Collect Baseline Data u Determine Process Capability u Complete Measure Tollgate Causes u Confirm Root Cause to Output Relationship u Estimate Impact of Root Causes on Key Outputs u Prioritize Root Causes u Value-Add Analysis u Takt Rate Analysis u Quick Wins u Statistical Analysis u Complete Analyze Tollgate Optimize Best Solutions u Develop ‘To-Be’ Value Stream Map(s) u Develop and Implement Pilot Solution u Implement 5 s Program u Develop Full Scale Implementation Plan u Cost/Benefit Analysis u Benchmarking u Complete Improve Tollgate u Implement Solution and Define Measure u Project Charter u Voice of the Customer and u Value Stream Mapping u Process Cycle Kano Analysis u SIPOC Map u Project Valuation/ROIC Analysis Tools u RACI and Quad Charts u Stakeholder Analysis u Communication Plan u Effective Meeting Tools u Inquiry and Advocacy Skills u Time Lines, Milestones, and Gantt Charting u Pareto Analysis Efficiency/Little’s Law u Operational Definitions u Data Collection Plan u Statistical Sampling u Measurement System Analysis (MSA) u Gage R&R u Kappa Studies u Control Charts u Spaghetti Diagrams u Histograms u Normality Test u Process Capability Analysis Analyze u Process Constraint ID and Takt Time Analysis u Cause & Effect Analysis u FMEA u Hypothesis Tests/Conf. Intervals u Simple & Multiple Regression u ANOVA u Components of Variation u Conquering Product and Process Complexity u Queuing Theory & Process Controls Ongoing Process Measurements u Confirm Attainment of Project Goals u Identify Project Replication Opportunities u Training u Complete Control Tollgate u Transition Project to Process Owner Improve u Replenishment Pull/Kanban u Stocking Strategy u Process Flow Improvement u Process Balancing u Analytical Batch Sizing u Total Productive Maintenance u Design of Experiments (DOE) u Solution Selection Matrix u Piloting and Simulation u Work Control System u Setup reduction u Pugh Matrix u Pull System Control u Mistake-Proofing/ Zero Defects u Standard Operating Procedures (SOP’s) u Process Control Plans u Visual Process Control Tools u MGPP u Statistical Process Controls (SPC) u Solution Replication u Visual Workplace u Metrics u Project Transition Model u Team Feedback Session Kaizen Events Targeted in Measure to Accelerate Results International Standards for Lean Six Sigma 2

Team Charter: Business Case & Project Description u Describe the project in non-technical terms n u ? Define the project’s scope and boundaries (locations, products, operations, etc) Is the scope reasonable? n Have key constraints and key assumptions been identified? n Where are you feeling the pain? u Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 3

Team Effectiveness u Ground Rules: u Team Roles: u Team Meeting Frequency: u Tools used by Team: u Team Issues: (Schedule, Vacations, Availability, Communication) u Other: Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 4

Project Charter Financial Impact Problem/Goal Statement Problem: Describe problem in non-technical terms u Statement should explain why project is important; why working on it is a priority Goal: Goals communicate “before” and “after” conditions n Shift mean, variance, or both? n Should impact cost, time, quality dimensions u Express goals using SMART criteria n Specific, Measurable, Attainable, Resource Requirements, Time Boundaries u Explain leverage and strategic implications (if any) Team projects) Tollgate Review Schedule PES Name Project Executive Sponsor (if different from PS) PS Name Project Sponsor/Process Owner DC Name Deployment Champion GB/BB Name Green Belt/Black Belt MBB Name Master Black Belt Core Team Role % Contrib. LSS Training u Team Member 1 SME XX YB u Team Member 2 TM XX GB u Team Member 3 SME XX PS Extended Team u Team Member 1 BFM XX Not Trained u Team Member 2 IT XX Not Trained u u u State financial impact of project n Expenses n Investments (inventory, capital, A/R) n Revenues u Separate “hard” from “soft” dollars u State financial impact of leverage opportunities (future Tollgate Scheduled Revised Define: XX/XX/XX Measure: XX/XX/XX Analyze: XX/XX/XX Improve: XX/XX/XX Control: XX/XX/XX u Review high-level schedule milestones here: n Phase Completions n Tollgate Reviews Complete XX/XX/XX XX/XX/XX Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 5

Voice of the Customer (VOC) Customer Voice of the Customer Key Customer Issue(s) Critical Customer Requirement Who is the Customer? What does the customer want from us? We need to identify the issue(s) that prevent us from satisfying our customers. We should summarize key issues and translate them into specific and measurable requirements u ? u ? u ? u ? u ? u ? u ? u ? Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 6

SIPOC Chart Suppliers l Supplier #1 l Supplier #2 l Supplier #3 Inputs l l Process Billing Dept. staff Customer database Shipping information Order information Input Metrics Billing Process Metrics Outputs l Delivered invoice l Delivered receipt Customers l Customer #1 l Customer #2 Output Metrics l ? l ? l ? l ? l ? l ? l ? Quality Speed Cost Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 7

Critical-to-Quality (CTQ) Tree Process Start: ? Strategic Item Process Stop: ? Functional Dept. Processes Quality Speed Cost Process Requirement: u ? Defect Definition: u ? u ? Unit of Measure: u ? Data Type: u ? u u ? ? Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 8

Schedule u Review high-level schedule milestones here Phase Completions n Gate Reviews n Executive Briefing n Tollgate Review Schedule Phase 1: Define Phase 2: Measure Tollgate Scheduled Revised Complete Define: XX/XX/XX - XX/XX/XX Measure: XX/XX/XX Analyze: XX/XX/XX Improve: XX/XX/XX Control: XX/XX/XX Phase 3: Analyze Phase 4: Improve Phase 5: Control Oct 10 Nov 10 Dec 10 Jan 11 Feb 11 Mar 11 Apr 11 Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 9

Business Impact State financial impact of future project leverage opportunities u Separate “hard or Type 1” from “soft Type 2 or 3” dollars u Annual Estimate Replicated Estimate Revenue Enhancement • Type 1: ? • Type 2: ? • Type 3: ? Expenses Reduction • Type 1: ? • Type 2: ? • Type 3: ? Loss Reduction • Type 1: ? • Type 2: ? • Type 3: ? Cost Avoidance • Type 1: ? • Type 2: ? • Type 3: ? Total Savings • Type 1: ? • Type 2: ? • Type 3: ? Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 10

Business Impact Details u Type 1: Describe the chain of causality that shows how you determined the Type 1 savings. (tell the story with cause–effect relationships, on how the proposed change should create the desired financial result (savings) in your project ) u Show the financial calculation savings and assumptions used. n Assumption #1 (i. e. source of data, clear Operational Definitions? ) n Assumption #2 (i. e. hourly rate + incremental benefit cost + travel) u 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 ) u Show the financial calculation savings and assumptions used. n Assumption #1 (i. e. Labor rate used, period of time, etc…) n Assumption #2 (i. e. contractor hrs or FTE, source of data, etc…) u Describe the Type 3 Business Impact(s) areas and how these were measured n Assumption #1 (i. e. project is driven by the Business strategy? ) n Assumption #2 (i. e. Customer service rating, employee moral, etc…) u Other Questions n Stakeholders agree on the project’s impact and how it will be measured in financial terms? n What steps were taken to ensure the integrity & accuracy of the data? n Has the project tracking worksheet been updated? Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 11

Communication Plan Audience Media Purpose Topics of Discussion/ Key Messages Owner Frequency Notes/Status Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 12

Current Status u Key actions completed Issues u Lessons learned u Communications, team building, organizational activities u Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 13

Next Steps Key actions u Questions to answer u Planned Lean Six Sigma Tool use u Barrier/risk mitigation activities u Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 14

Sign Off u I concur that the Define phase was successfully completed on MM/DD/YYYY u I concur the project is ready to proceed to next phase: Measure Enter Name Here Green Belt/Black Belt Enter Name Here Deployment Champion Enter Name Here Sponsor / Process Owner Enter Name Here Financial Representative Master Black Belt Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 15

Tollgate Reviews Backup Slides Go Forward D ld o H t l Ha M Wait - Go Back A I C

Define Tollgate Checklist q Is this project important, i. e. has the project been chosen because it is in alignment with q q q q q business goals and the strategic direction of the ‘business’? What is the problem statement – detailing (what) is the problem, (when) was the problem first seen, (where) is it seen, and what is the (magnitude or extent) of the problem. Is the problem measured in terms of Quality, Cycle Time or Cost Efficiency, or direct financial benefits? Ensure there is no mention or assumptions about causes and solutions. Does a goal statement exist that defines the results expected to be achieved by the process, with reasonable and measurable targets? Is the goal developed for the “what” in the problem statement, thus measured as Quality, Cycle Time, or Cost Efficiency metric? Does a financial business case exist, explaining the potential impact (i. e. measured in dollars) of the project on the process, department, division, suppliers, customers, etc. ? Is the project scope reasonable? Have constraints and key assumptions been identified? Have IT implications been addressed and coordinated with IT managers? Who is on the team? Are they the right resources and has their required time commitment to the project been confirmed by Management and Deployment Team? What is the high level work plan? What are the key milestones (i. e. dates of tollgate reviews for DMAIC projects)? Who are the customers (internal/external) for this process? What are their requirements? Are they measurable? How were the requirements determined? Who are the key stakeholders? How will they be involved in the project? How will progress be communicated to them? Do they agree to the project? What kinds of barriers/obstacles will need assistance to be removed? Has the development of a risk mitigation plan to deal with the identified risks been developed? Key Deliverables: q SIPOC q Process Map and/or Value Stream Map q Communication Plan q Validated Project Charter q Initial Work Plan q Risk Mitigation Plan q Deliverables Uploaded to Central Storage Location or Deployment Management System. Stop Tollgate Review Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 17

Lean Six Sigma DMAIC Improvement Process u Define Stop Define the opportunity from both the customer and business perspective Tollgat e Measure Review Stop Understand the baseline process performance u Tollgat u e Analyze Review Stop Tollgat e Review Stop Identify the critical X factors and root causes impacting process performance Improve u Develop solutions linked to critical x’s Tollgat e Review Control u Implement solutions & control plan Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 18

Measure Tollgate Checklist q Has a more detailed Value Stream Map been completed to better understand the q q q process and problem, and where in the process the root causes might reside? Has the team conducted a value-added and cycle time analysis, identifying areas where time and resources are devoted to tasks not critical to the customer? Has the team identified the specific input (x), process (x), and output (y) measures needing to be collected for both effectiveness and efficiency categories (i. e. Quality, Speed, and Cost measures)? Has the team developed clear, unambiguous operational definitions for each measurement and tested them with others to ensure clarity/consistent interpretation? Has a clear, reasonable choice been made between gathering new data or taking advantage of existing data already collected by the organization? Has an appropriate sample size and sampling frequency been established to ensure valid representation of the process we’re measuring? Has the measurement system been checked for repeatability and reproducibility, potentially including training of data collectors? Has the team developed and tested data collection forms or check sheets which are easy to use and provide consistent, complete data? Has baseline performance and process capability been established? How large is the gap between current performance and the customer (or project) requirements? Has the team been able to identify any complete ‘Quick Wins’? Have any Kaizen opportunities been identified to accelerate momentum and results? Have key learning(s) to-date required any modification of the Project Charter? If so, have these changes been approved by the Project Sponsor and the Key Stakeholders? Have any new risks to project success been identified, added to the Risk Mitigation Plan, and a mitigation strategy put in place? Key Deliverables: q q q Detailed Value Stream Map(s) Data Collection Plan Measurement Collection Results Process Capability Results Current Baseline Process Performance q Quick Wins, if applicable q Identification of Kaizen Opportunities, if applicable q Refined Charter, as necessary q Updated Risk Mitigation Plan q Deliverables Uploaded to Central Storage Location or Deployment Management System. Stop Tollgate Review Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 19

Responsibility Grid (Optional) Responsibility Grid Master Project Deployment Executive Green Belt Black Belt Sponsor Champion Leader Customer Charter Define Measure Analyze Improve Control Decision 1 = should be the only one to make this decision 2 = should have veto power over this decision 3 = should be one of those who votes Execution A = has to execute B = has to assist in execution (provide information, …) C = not involved in execution Responsibility P = Perform A = Approve R = Review Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 20

Strategy - Thought Map (Optional) Are the team members identified? Problem Has the CTQ’s been defined? Are the CTQ’s measurable? Are my champions & Controller briefed? Critical variables identified? Is Y=F(X) established? Can we control X’s? Do we have a measurement system? Can we have dashboards on X’s? Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 21

Customer Segmentation Matrix (Optional) Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 22

Kano Analysis Chart (Optional) Ranking of Customer Needs Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 23

VOC Plan (Optional) Process Name: Project Name: Created By: Date Initiated: Location: Current Revision Date: Customers and Segments • List the various customers (external) and other key stakeholders (business partners, regulatory agencies, etc. ) of your process. Are there different types of stakeholders who may have very different needs? If so, list these as different segments. • ? What You Want to Know Develop a list of specifically what you want to know about your customers and other stakeholders needs. Use the following list as a guide: What are the most important process outputs (products/services)? What is the performance level of the important outputs? What are the problems with the outputs? What is their impact? What do you like about _______? What can be improved about _______? What can be done to make your job easier? What specific recommendations would you make to us? How do we compare relative to our competitors? How easy is it to do business with us? • • • ? ? ? ? ? Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 24

VOC Plan (Cont. ) (Optional) Information Sources (Check the data sources that you think will be most useful) Reactive Data Proactive Data Complaints Problem or service hot lines Technical support calls Customer service calls Claims, credits Sales reporting Product return information Warranty claims Web page activity Interviews Focus groups Surveys Comment cards Sales visits/calls Direct observation Market research/monitoring Benchmarking Other: VOC Collection Plan Summary • Summarize your plans to gather and use both reactive and proactive sources of VOC information. Indicate how much data you will get, how you will get it, and when. Include, for instance: What specific sources of data you plan on exploring The number of interviews or surveys you plan to use Which customers you will contact The amount of data you will collect - When you will start and end the data collection How you plan on analyzing the gathered information Etc. • • • ? ? ? ? ? Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 25

Quality Functional Deployment (QFD) (Optional) Importance Ratings Strong Impact 9 Moderate Impact 3 Weak Impact 1 Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 26

Project Definition: Includes/Excludes (Optional) Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 27

SWOT Analysis (Optional) Strength Weakness ? u ? u Long Term Short Term Opportunity Threat u ? u ? u ? u u ? u ? Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 28

Multi-Generational Project Plan (Optional) Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 29

Process Bottleneck Identification & Workload Balancing (Optional) u Takt Rate Analysis compares the task time of each process (or process step) to: n Each other to determine the time trap n Customer demand to determine if the time trap is the constraint Takt Time = Net Process Time Available Number of Units to Process Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 30

Influence Strategy (Optional) Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 31

RACI Chart (Optional) R = Responsible – The person who performs the action/task. A = Accountable – The person who 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. Step Action/Task Responsible Accountable Consulted Informed 1 2 3 4 5 6 7 8 9 10 Enter Key Slide Take Away (Key Point) Here International Standards for Lean Six Sigma 32