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Problem Solving using Six Sigma

The document outlines the Six Sigma methodology, focusing on its phases: Define, Measure, Analyze, Improve, and Control (DMAIC). It emphasizes the importance of identifying customer requirements, measuring current performance, and using data-driven approaches to reduce variation and improve processes. Additionally, it discusses tools like process mapping, Pareto analysis, and the affinity diagram to enhance understanding and facilitate project success.

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Stand Problem Solving using Six Sigma Methodology
© alpha2infinity variation 2 Variation leads to Waste DENTIST 1. Waiting 2. Over Production 3. Over Processing 4. Inventory 5. Motion 6. Transportation 7. Defects 8. Talent Six Sigma Lean
© alpha2infinity six sigma phases 3 Measure Y = f(x1, x2, …, xn) Analyze Y = f(x1, x2, …, x9) Improve Y = f(x1, x2, x3) Control Define Project Y • Define project scope. Begin & End • Define Project Y. How will we measure success? • Ensure good Measurement System • Measure current performance • Map the process and identify ALL variables that can affect performance • Analyze existing process data • Identify significant process variables affecting performance • Experiment to determine set points of critical process inputs to control process • Implement new improved process • Demonstrate performance of new improved process • Develop plans to sustain improvement 6Sigma aka DMAIC is a data-driven, variation reduction methodology
© alpha2infinity typical six sigma project 4 O special cause 0 5 10 15 20 25 30 35 40 -4 -2 0 2 4 6 8 10 12 14 16 DefectRate Time, weeks Define Improve ControlMeasure & Analyze Defects Defects Characterization & Understanding Improving & Optimizing
© alpha2infinity why define? 5 “If I had only one hour to save the world, I would spend fifty- five minutes defining the problem, and only five minutes finding the solution” Define
© alpha2infinity why define? 6 Define Without Define, we spin our wheels and waste time & money
© alpha2infinity agenda 7 DEFINE  Identify the vital few • Bound the problem • Understand customer requirements • Prioritize customer requirements • Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity identify the vital few Trivial Many Vital Few
© alpha2infinity pareto analysis 9 1858 - 1923 Vilfredo Pareto was an Italian engineer, sociologist, economist and philosopher. Observed that 80% of the land in Italy was owned by 20% of the population. Focus on the Vital Few
© alpha2infinity pareto chart Pareto is a Sorting Tool Things to work on
© alpha2infinity agenda 11 DEFINE  Identify the vital few  Bound the problem • Understand customer requirements • Prioritize customer requirements • Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity a process view • Everything is a process. • The quality of a product or service is directly related to the quality of the process. • As change agents, we must address the process as a whole in order to deliver real change. • We start with SIPOC – a high level view of the process Suppliers Inputs OutputsProcess Customers
© alpha2infinity SIPOC OS PI C Step A Step B Step C Step D Step E START STOP List ~5 High Level Steps to describe entire process • Helps define project scope. Begin & End boundaries • Helps define potential areas of improvement • Helps identify customers impacted by your project • Helps identify suppliers of inputs affecting your process
© alpha2infinity SIPOC 1. Define First & Last step. Break process into ~5 steps 2. List the major inputs of each step. 3. Identify suppliers of each input. Identify major suppliers. 4. List the major outputs of each step. 5. Finally identify customers for each output. People Impacted
© alpha2infinity agenda 15 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements • Prioritize customer requirements • Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity customer requirements 16 All customer requirements are not equal. They fall into 3 categories: Basic → Performance → Delighter. And change over time. Delighter: These needs provide satisfaction when met, but do not cause dissatisfaction when unmet. Since these attributes are unexpected, they delight customers, and are often unimagined and unspoken. Performance: These needs result in satisfaction when met and dissatisfaction when unmet. Delivering more of these needs result in increased customer satisfaction. These are attributes that are verbalized and the ones in which companies compete. Basic: These needs are taken for granted when met, but result in dissatisfaction when unmet. Meeting these needs do not result in increased customer satisfaction. Since customers expect these attributes and view them as basic, they are unlikely to talk about them.
© alpha2infinity KANO model 17 Time Delighter (Unknown) Basic (Unspoken) What happens over time?? Performance (Spoken) Did it Poorly Did it Very well
© alpha2infinity hotel example 18 KANO example for hotel selection
© alpha2infinity gathering Voice of Customer 19 Reactive Approach • Looks at historical data to determine issues, unmet needs, problems & interests of former customers. o Customer complaints o Customer service calls o Product return information o Warranty claims o Web page activity Proactive Approach • Verify conclusions of reactive research • Determine interests & unmet needs of future customers o Surveys o Interviews o Market research o Benchmarking o Observe customers  Takes more effort but is often more powerful than reactive research!
© alpha2infinity VOC technique: listen LISTEN to Customers  Survey  Interviews  Focus Groups
© alpha2infinity VOC technique: observe OBSERVE Customer behavior  Focus Groups  Go & See  Ethnography Studies
© alpha2infinity affinity diagram 22 The affinity diagram is a tool used to organize ideas and language data. This method was developed by a noted Japanese anthropologist in the 1950s called Jiro Kawakita. He was confronted with a need to summarize large quantities of factual language data from his field research. He had an “aha” moment about grouping the data and distilling it into useful fundamental messages.
© alpha2infinity voice(s) of customer Normally my husband puts appliances together, but not this one. It was very easy to assemble the item. After meeting with the customers, write down one key customer insight that you heard or saw per Post-it Vote to select top 20
© alpha2infinity affinity diagram Ease of Assembly Category 2 Category 4Category 3 Lone Wolf Group images into similar categories Work until ≤ 5 categories Category Titles are Drivers in CTQ tree
© alpha2infinity agenda 25 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements • Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity critical to quality 26 A CTQ (critical-to-quality) is a specific measurable characteristic of a product or service that fulfils the expressed requirement of the customer. CTQ performance must exceed specifications to satisfy the customer. Hard to measure Easy to measure Need Drivers CTQs Specification Rich 1.1 < TDS > 1.3 Not Acidic Extraction > 18% Not Bitter Extraction < 22% > 140°F < 176°F Price < $1.99 / medium Taste Temperature Cost Customer wants "good coffee" Optimum drinking temperature We need to translate VOC to CTQs
© alpha2infinity CTQ tree 27 • Only 1 CTQ / Project • Cannot improve Project CTQ at expense of other CTQs Cannot rob Peter to pay Paul
© alpha2infinity agenda 28 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity stakeholders Stakeholder: Anyone impacted by your projectTeachers Principal Team Members You Stakeholders can be inside & outside the organization
© alpha2infinity why stakeholder analysis? • Provide resources • Give advice • ‘lobby’ for your cause • Break down barriers • Accelerate and improve results • Withhold resources • Withhold expertise • Convince others to withhold support • Create barriers • Delay and sabotage
© alpha2infinity stakeholder analysis Stakeholder analysis is a critical because it influences: Resources, Solutions and ultimately Project success! So we need to be Proactive about identifying and managing Stake Holders
© alpha2infinity agenda 32 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity before project begins Needs Approval & Sponsor Team
© alpha2infinity project charter Project Charter is a good executive communication tool
© alpha2infinity agenda 35 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity measure phase 36 Measure Y = f(x1, x2, …, xn) Analyze Y = f(x1, x2, …, x9) Improve Y = f(x1, x2, x3) Control Define Project Y • Define project scope. Begin & End • Define Project Y. How will we measure success? • Ensure good Measurement System • Measure current performance • Map the process and identify ALL variables that can affect performance • Analyze existing process data • Identify significant process variables affecting performance • Experiment to determine set points of critical process inputs to control process • Implement new improved process • Demonstrate performance of new improved process • Develop plans to sustain improvement
© alpha2infinity process mapping Everything is a process. What is Process Mapping? Graphical illustration of the work process When do you apply process mapping? Always What are benefits of Process Mapping? Identify major tasks / activities that are performed Identify sequence of tasks / activities Identify accountability of task /activities Identify process inputs that affect process output Tools Required 1. Room with large wall 2. X-functional team (6 – 8) 3. Experts on the process 4. Sharpie Markers 5. Large colored Post-it Start with SIPOC Complete Flow chart Complete Process Map
© alpha2infinity flowchart symbols Start / Stop Action (verb / noun) Decision Y N Delay or Wait Documentation Or Paperwork Movement
© alpha2infinity flowchart example Start Drive to Airport Park the Car Walk to Terminal Wait in Line Security Check Walk to Gate Wait for Boarding Stop ID Check e-ticket? bags?Walk to security Walk to Counter Print B. Pass Board Plane N Y N Check bags Wait in Line Wait in Line List + Sequence of Actions, Delays, Decisions and Movement
© alpha2infinity Fishbone Originally developed by Prof. Kaoru Ishikawa to show the causes of a specific effect, this tool encourages the team to think of inputs in categories of: Personnel, Measurement, Environment, Material, Machine & Method (6Ms).
© alpha2infinity fishbone 41 Fishbone Diagram is useful in identifying all inputs to a process step. Ideally, create a fishbone for every major process step
© alpha2infinity process mapping 42 • List Inputs and Outputs for each Action Step • Goal is to identify ALL process inputs. • Some of these are the cause of undesired variation
© alpha2infinity agenda 43 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity cause & effect matrix 44 Major process outputs & their importance Major process inputs Higher Scores are more important Collect data on Project Y & process inputs (Xs) for subsequent analysis
© alpha2infinity agenda 45 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity types of data DATA Attribute Variable Binomial Data can have only 2 values • pass/fail, yes/no Poisson Data can have any discrete value • A+, A, A-, B+, B, B-,… F Data can have any value on continuous scale Normal t-distribution lognormal Weibull triangular uniform & many more! COUNT MEASURE
© alpha2infinity sample v population Population estimate Study the sample to make inferences about the population Sample mini-population
© alpha2infinity common statistics DATA Attribute Variable Location • mean • median • mode Spread • range • standard deviation • variance Shape • skewness • kurtosis Counts (Poisson) Proportions (binomial)
© alpha2infinity location Mean: the total of values divided by the number of values; • (2 + 1 + 2 + 3 + 4 + 5) / 6 = 2.83 • Is sensitive to extreme scores Median: the middle value after a set of values has been sorted (low to high) • 1, 2, 2, 3, 4, 5; the median is 2.5 • Is robust to extreme scores Mode: the value that occurs most frequently; • 1, 2, 2, 3, 4, 5; the mode is 2 • A data set may contain multiple modes; multimodal Consider a sample: 2, 1, 2, 3, 4, 5
© alpha2infinity spread Range: max value – min value • Range = 5 -1 = 4 • Is a poor estimator of variation; relies only on extreme values; ignoring most values Standard Deviation: the average distance of a data point from the mean • Most commonly used; has same units as the mean • Average distance from the mean • Less sensitive to outliers than the range Variance: (standard deviation)2 Consider a sample: 2, 1, 2, 3, 4, 5
© alpha2infinity normal distribution Many natural phenomena and man-made processes follow a “normal” distribution. It is a continuous distribution and can be described by its mean and standard deviation. Different Mean Same Standard Deviation Same Mean Different Standard Deviation
© alpha2infinity shape Positive Negative SKEWNESS symmetry Platykurtic Leptokurtic KURTOSIS ‘peakedness’ Mean Median Mode
© alpha2infinity property of normal distribution The area under the normal curve can be used to estimate the probability of an “event” occurring. If data is NOT normal (i.e. misshapen), these probabilities change. 3210-1-2-3 0.4 0.3 0.2 0.1 0.0 X Density 95% 99.73% 68% Ordinary UnusualUnusual
© alpha2infinity normality check 54 If probability of observing normality test statistic > 5%, data is normal
© alpha2infinity other continuous distributions 55
© alpha2infinity agenda 56 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity why evaluate measurement system? 57 Observed Variation Variation from Process Variation from Measurement Due to Gage - accuracy Due to Operator - precision Need to ensure that at least 90% of what we are observing is from process. 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑜𝑏𝑠𝑒𝑟𝑣𝑒𝑑 = 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 + 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡 Repeatability Reproducibility
© alpha2infinity accuracy & precision 58 Measurement quality is described by accuracy & precision Accuracy = Average value from target Calibration Study Precision = Variation amongst data points Gage R&R Study
© alpha2infinity repeatability 59 Repeatability = agreement with self (attribute data) variation from one operator (variable data) Good Repeatability 1 3 2 Poor Repeatability 1 3 2 Test Conditions - same part - same gage - same operator 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡 = 𝑽𝒂𝒓𝒊𝒂𝒕𝒊𝒐𝒏 𝒓𝒆𝒑𝒆𝒂𝒕𝒂𝒃𝒊𝒍𝒊𝒕𝒚 + 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑟𝑒𝑝𝑟𝑜𝑑𝑢𝑐𝑖𝑏𝑖𝑙𝑖𝑡𝑦
© alpha2infinity reproducibility 60 Jerry Bob Mike Good Reproducibility Bob Mike Jerry Poor Reproducibility Reproducibility = agreement between operators (attribute data) variation from different operators (variable data) Test Conditions - same part - same gage - different operators 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡 = 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑟𝑒𝑝𝑒𝑎𝑡𝑎𝑏𝑖𝑙𝑖𝑡𝑦 + 𝑽𝒂𝒓𝒊𝒂𝒕𝒊𝒐𝒏 𝒓𝒆𝒑𝒓𝒐𝒅𝒖𝒄𝒊𝒃𝒊𝒍𝒊𝒕𝒚 Measurement System Analysis should be performed for all Process CTQs (outputs of customer value)
© alpha2infinity gage R&R attribute data 61 70% 90% Kappa
© alpha2infinity gage R&R variable data 62 28% 14% %GRR
© alpha2infinity agenda 63 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity capability 64 Capability Studies determine process performance from the point of view of the customer! Voice of The Process Voice of The Customer 1USLLSL Specifications From Customer 𝐶𝑎𝑝𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝐶𝑝 = 𝑉𝑂𝐶 (𝑇𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒) 𝑉𝑂𝑃 (𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝑆𝑝𝑟𝑒𝑎𝑑) = (𝑈𝑆𝐿 − 𝐿𝑆𝐿) 𝟔𝜎 99.73%
© alpha2infinity capability concept 65 TOLERANCE PROCESS TOLERANCE PROC. Capability = 1 3210-1-2-3 0.4 0.3 0.2 0.1 0.0 Capability = 2 3210-1-2-3 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 Cpk is a metric used to measure process capability
© alpha2infinity capability metric, Cpk 66 𝐶𝑝𝑘 = 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑓𝑟𝑜𝑚 𝑋 𝑡𝑜 𝑛𝑒𝑎𝑟𝑒𝑠𝑡 𝑠𝑝𝑒𝑐 3𝜎 𝐶𝑝𝑘 = 𝑀𝑖𝑛 𝐶 𝑝𝐿, 𝐶 𝑝𝑈 𝐶 𝑝𝐿 = 𝑋 − 𝐿𝑆𝐿 3𝜎 𝐶 𝑝𝑈 = 𝑈𝑆𝐿 − 𝑋 3𝜎 Variable Data Attribute Data 𝐶𝑝𝑘 = 𝑃𝑟𝑜𝑝𝑜𝑟𝑡𝑖𝑜𝑛 𝑂𝑢𝑡𝑠𝑖𝑑𝑒 𝑠𝑝𝑒𝑐 0.20 0.15 0.10 0.05 0.00 Probability 11 0.01147 0 𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑅𝑎𝑡𝑒 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝐹𝑎𝑖𝑙𝑒𝑑 𝑁𝑢𝑚𝑏𝑒𝑟 𝐼𝑛𝑠𝑝𝑒𝑐𝑡𝑒𝑑 The failure rate can be converted to Cpk Customer Requirement Specification Capability Study should be performed for all Process CTQs
© alpha2infinity capability calculation 67 Cpk for Attribute Data 1.3 2.0 Cpk Cpk of 2 is 6 sigma process 3.4 defects in 1,000,000 Cpk for Variable Data
© alpha2infinity analyze phase 68 Measure Y = f(x1, x2, …, xn) Analyze Y = f(x1, x2, …, x9) Improve Y = f(x1, x2, x3) Control Define Project Y • Define project scope. Begin & End • Define Project Y. How will we measure success? • Ensure good Measurement System • Measure current performance • Map the process and identify ALL variables that can affect performance • Analyze existing process data using appropriate hypothesis test • Identify significant process inputs • Experiment to determine set points of critical process inputs to control process • Implement new improved process • Demonstrate performance of new improved process • Develop plans to sustain improvement
© alpha2infinity agenda 69 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity hypothesis testing 70 Our Decision X has NO effect on Y X has an effect on YTheAbsoluteTruth XhasNO effectonY  a error Seeing something not present Xhasan effectonY b error Miss seeing something that is present  In the measure phase, we identified all ‘potential’ causes of problem. In analyze phase we will examine data to identify the ‘significant’ causes.
© alpha2infinity hypothesis test selection 71 SingleY Single X Attribute Variable Attribute Chi2 Logistic Regression Variable t-test ANOVA Medians Linear Regression 1. Based on data type select the correct Hypothesis test 2. All Hypothesis tests calculate the probability of a error and report it as p-value. 3. IF p-value is < 0.05, we are at least 95% confident that the X has a significant effect on Y
© alpha2infinity scenarios 72 Is there a difference in burrito size between Chipotle & Moe’s? Parameter Description Type of Data Y X Hypothesis Test Weight of Burrito Variable Burrito Shop Attribute ANOVA (t-test) Does the age of male customer affect the type of car they buy? Parameter Description Type of Data Y X Hypothesis Test Type of Car Attribute Age Variable Logistic Regression
© alpha2infinity scenarios 73 Does the air pressure effect how far TB12 can throw a football? Parameter Description Type of Data Y X Hypothesis Test Distance Thrown Variable Air Pressure Variable Regression Parameter Description Type of Data Y X Hypothesis Test Hire: yes, no Attribute Age: young, old Attribute Chi-Square The HR department wants to see if there is a link between age (old and young) and whether that person gets hired
© alpha2infinity agenda 74 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity chi2 test - Enter Data - Evaluate p-value - Make Conclusion
© alpha2infinity agenda 76 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity t-test 77 Use to compare means of TWO groups
© alpha2infinity mann-whitney test 78 When data is NOT normal, compare medians.
© alpha2infinity between ANOVA 79 𝑊𝑖𝑡ℎ𝑖𝑛 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 = 𝑋𝑖 − 𝑋𝑖𝑗 2 𝐵𝑒𝑡𝑤𝑒𝑒𝑛 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 = 𝑋𝑖 − 𝑋 2 𝐹 = 𝐵𝑒𝑡𝑤𝑒𝑒𝑛 𝑊𝑖𝑡ℎ𝑖𝑛 = 𝑆𝑖𝑔𝑛𝑎𝑙 𝑁𝑜𝑖𝑠𝑒 is F = 1? X2 𝑟1 𝑟2 𝑟3 X1 𝑏3 𝑏2 𝑏1 between Called ANalysis Of VAriance, but we make conclusions about Means
© alpha2infinity ANOVA 80 Use to determine if means of > TWO groups are all equal
© alpha2infinity mood’s median test 81 When data is NOT normal, analyze medians.
© alpha2infinity agenda 82 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity Regression 83 Variation in Y explained by Model 1. Is there a linear relationship between X and Y? 2. Can the X predict the Y value?? i.e Equation 3. & if yes, how good is this prediction???
© alpha2infinity improve phase 84 Measure Y = f(x1, x2, …, xn) Analyze Y = f(x1, x2, …, x9) Improve Y = f(x1, x2, x3) Control Define Project Y • Define project scope. Begin & End • Define Project Y. How will we measure success? • Ensure good Measurement System • Measure current performance • Map the process and identify ALL variables that can affect performance • Analyze existing process data using appropriate hypothesis test • Identify significant process inputs • Experiment to determine set points of critical process inputs to control process • Implement new improved process • Demonstrate performance of new improved process • Develop plans to sustain improvement
© alpha2infinity agenda 85 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE  Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity DOE 86 In the ANALYZE phase we looked at existing data. In the IMPROVE phase, we conduct experiments using a systematic method to determine cause-and-effect relationships between inputs into a process (factors) and the output of that process (response). Process Inputs (Factors) – Change brand of gas  Octane rating (85, 90)  Driving Speed (55, 60) – Tune-up Car – New tires  Tire Pressure (30, 35)  Significant Inputs identified in analyze phase Process Output (Response) – Fuel efficiency Specification: > 30 mpg Driving (Process)
© alpha2infinity DOE setup 87 - Enter set points of factors to setup experimental conditions - Enter response values of experimental runs
© alpha2infinity DOE 88 - Evaluate p-value to identify critical factor(s) - Determine contribution of each factor (practical)
© alpha2infinity agenda 89 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE  Design of Experiments  Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity brainstorming 90 Brainstorming is a tool for generating as many ideas or solutions to a problem. Ideas should be as broad and wide as possible. There are no bad ideas. However it is not a tool for determining the best solution to the problem. Brainstorming should be done with a team
© alpha2infinity brainstorming Methods 91 Free-wheeling brainstorm: • Team members call out their ideas spontaneously. • The scribe records the ideas as they are suggested. Round-robin brainstorming: • The facilitator asks each member, in turn, for an idea. • Members may pass on any round. • The facilitator records the ideas. The session continues until team members have no more ideas to add. The slip method: • The facilitator asks members to write down their ideas on Post-its. • Post-its are placed on wall for everyone to read. • Allow team to write new ideas after reading the Post-its • All ideas are then collected and organized (No duplication, Clarity). 
© alpha2infinity agenda 92 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE  Design of Experiments  Brainstorming  Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity ideabox 93 Idea Box is a creativity technique based on concepts (morphological analysis) developed by Fritz Zwicky a Swiss astrophysicist in the 1940's. 1. Write down the problem statement 2. Break down the problem into smaller elements (think SIPOC) 3. Lists options for each element 4. Pick options that combine into ‘best’ solution
© alpha2infinity ideabox This technique results in many permutations The art lies in picking the best combination to solve the problem
© alpha2infinity agenda 95 DEFINE  Identify the vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE  Design of Experiments  Brainstorming  Idea Box  Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
© alpha2infinity selecting a solution 96 Quality S1 S2 S3 S4 Mary 1 2 3 4 Peter 2 1 3 4 Priya 1 2 3 4 Chelsea 1 2 3 4 TOTAL 5 7 12 16 Each person ranks Each solution against Each criteria. The total score is entered into the matrix and solutions are ranked from best
© alpha2infinity agenda 97 DEFINE • Pareto of problems • Bounding the problem • KANO & ‘Voice of Customer’ • Why talk to all customers? • Project Charter MEASURE • Process Mapping • Fishbone • Basic Statistics • Measurement System Analysis • Capability ANALYZE • Hypothesis Testing • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL  Demonstrate improvement • Write Instructions • Develop control plan • Monitor new process
© alpha2infinity B v C comparison 98 Analyze data from old & new process Evaluate if 1. New process is better? (t-test) 2. Is it good enough? (new Cpk)
© alpha2infinity agenda 99 DEFINE • Pareto of problems • Bounding the problem • KANO & ‘Voice of Customer’ • Why talk to all customers? • Project Charter MEASURE • Process Mapping • Fishbone • Basic Statistics • Measurement System Analysis • Capability ANALYZE • Hypothesis Testing • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL  Demonstrate improvement  Write Instructions • Develop control plan • Monitor new process
© alpha2infinity examples of SOP 100 Too Wordy Succinct, Multi-Lingual, Minimal Reading
© alpha2infinity101 List inputs, required operations & expected outputs for each process step
© alpha2infinity agenda 102 DEFINE • Pareto of problems • Bounding the problem • KANO & ‘Voice of Customer’ • Why talk to all customers? • Project Charter MEASURE • Process Mapping • Fishbone • Basic Statistics • Measurement System Analysis • Capability ANALYZE • Hypothesis Testing • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL  Demonstrate improvement  Write Instructions  Develop control plan • Monitor new process
© alpha2infinity control plan 103 Complete all sections of control plan, particularly - current controls & - reaction plans for key process outputs
© alpha2infinity agenda 104 DEFINE • Pareto of problems • Bounding the problem • KANO & ‘Voice of Customer’ • Why talk to all customers? • Project Charter MEASURE • Process Mapping • Fishbone • Basic Statistics • Measurement System Analysis • Capability ANALYZE • Hypothesis Testing • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL  Demonstrate improvement  Write Instructions  Develop control plan  Monitor new process
© alpha2infinity control chart 105 Investigate root cause of any out-of-control incident.
© alpha2infinity pre-control chart 106 Run in green zone, Reset in red zone, Investigate if in between
Stand Thank You

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In this document
Powered by AI

Introduction to problem solving using the Six Sigma methodology.

Identifies eight variations that lead to waste: Waiting, Overproduction, Overprocessing, Inventory, Motion, Transportation, Defects, Talent.

Outlines DMAIC phases: Define, Measure, Analyze, Improve, Control; emphasizes process data and project scope.

Illustrates a timeline of defect rate during a Six Sigma project, highlighting the stages: Define, Measure, Analyze, Improve, and Control.

Stress on the significance of defining the problem thoroughly before jumping to solutions, highlighting time and resource efficiency.

Detailed agenda outlining the essential steps in Six Sigma projects: Define, Measure, Analyze, Improve, Control.

Explains customer needs categorized into Basic, Performance, and Delighter based on their impact on satisfaction.

Details techniques used to gather Voice of Customer data through reactive and proactive research.

Explains process mapping fundamentals including flowcharts and Fishbone diagrams to visualize processes.

Introduces fundamental concepts like population, sample, and common statistical measures for data analysis.

Discusses accuracy vs. precision in measurement systems, including repeatability and reproducibility.

Explains process capability metrics, including Cp, Cpk, and how to evaluate customer specifications.

Discusses types of hypothesis tests, including their application in analyzing data for significant causes.

Techniques for brainstorming and the process for selecting the best solutions through team inputs.

Outlines components of control plans, including control charts and reaction plans for maintaining process stability.

Problem Solving using Six Sigma

  • 1.
  • 2.
    © alpha2infinity variation 2 Variation leadsto Waste DENTIST 1. Waiting 2. Over Production 3. Over Processing 4. Inventory 5. Motion 6. Transportation 7. Defects 8. Talent Six Sigma Lean
  • 3.
    © alpha2infinity six sigmaphases 3 Measure Y = f(x1, x2, …, xn) Analyze Y = f(x1, x2, …, x9) Improve Y = f(x1, x2, x3) Control Define Project Y • Define project scope. Begin & End • Define Project Y. How will we measure success? • Ensure good Measurement System • Measure current performance • Map the process and identify ALL variables that can affect performance • Analyze existing process data • Identify significant process variables affecting performance • Experiment to determine set points of critical process inputs to control process • Implement new improved process • Demonstrate performance of new improved process • Develop plans to sustain improvement 6Sigma aka DMAIC is a data-driven, variation reduction methodology
  • 4.
    © alpha2infinity typical sixsigma project 4 O special cause 0 5 10 15 20 25 30 35 40 -4 -2 0 2 4 6 8 10 12 14 16 DefectRate Time, weeks Define Improve ControlMeasure & Analyze Defects Defects Characterization & Understanding Improving & Optimizing
  • 5.
    © alpha2infinity why define? 5 “IfI had only one hour to save the world, I would spend fifty- five minutes defining the problem, and only five minutes finding the solution” Define
  • 6.
    © alpha2infinity why define? 6 Define WithoutDefine, we spin our wheels and waste time & money
  • 7.
    © alpha2infinity agenda 7 DEFINE  Identifythe vital few • Bound the problem • Understand customer requirements • Prioritize customer requirements • Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 8.
    © alpha2infinity identify thevital few Trivial Many Vital Few
  • 9.
    © alpha2infinity pareto analysis 9 1858- 1923 Vilfredo Pareto was an Italian engineer, sociologist, economist and philosopher. Observed that 80% of the land in Italy was owned by 20% of the population. Focus on the Vital Few
  • 10.
    © alpha2infinity pareto chart Paretois a Sorting Tool Things to work on
  • 11.
    © alpha2infinity agenda 11 DEFINE  Identifythe vital few  Bound the problem • Understand customer requirements • Prioritize customer requirements • Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 12.
    © alpha2infinity a processview • Everything is a process. • The quality of a product or service is directly related to the quality of the process. • As change agents, we must address the process as a whole in order to deliver real change. • We start with SIPOC – a high level view of the process Suppliers Inputs OutputsProcess Customers
  • 13.
    © alpha2infinity SIPOC OS PIC Step A Step B Step C Step D Step E START STOP List ~5 High Level Steps to describe entire process • Helps define project scope. Begin & End boundaries • Helps define potential areas of improvement • Helps identify customers impacted by your project • Helps identify suppliers of inputs affecting your process
  • 14.
    © alpha2infinity SIPOC 1. DefineFirst & Last step. Break process into ~5 steps 2. List the major inputs of each step. 3. Identify suppliers of each input. Identify major suppliers. 4. List the major outputs of each step. 5. Finally identify customers for each output. People Impacted
  • 15.
    © alpha2infinity agenda 15 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements • Prioritize customer requirements • Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 16.
    © alpha2infinity customer requirements 16 Allcustomer requirements are not equal. They fall into 3 categories: Basic → Performance → Delighter. And change over time. Delighter: These needs provide satisfaction when met, but do not cause dissatisfaction when unmet. Since these attributes are unexpected, they delight customers, and are often unimagined and unspoken. Performance: These needs result in satisfaction when met and dissatisfaction when unmet. Delivering more of these needs result in increased customer satisfaction. These are attributes that are verbalized and the ones in which companies compete. Basic: These needs are taken for granted when met, but result in dissatisfaction when unmet. Meeting these needs do not result in increased customer satisfaction. Since customers expect these attributes and view them as basic, they are unlikely to talk about them.
  • 17.
    © alpha2infinity KANO model 17 Time Delighter (Unknown) Basic (Unspoken) Whathappens over time?? Performance (Spoken) Did it Poorly Did it Very well
  • 18.
    © alpha2infinity hotel example 18 KANOexample for hotel selection
  • 19.
    © alpha2infinity gathering Voiceof Customer 19 Reactive Approach • Looks at historical data to determine issues, unmet needs, problems & interests of former customers. o Customer complaints o Customer service calls o Product return information o Warranty claims o Web page activity Proactive Approach • Verify conclusions of reactive research • Determine interests & unmet needs of future customers o Surveys o Interviews o Market research o Benchmarking o Observe customers  Takes more effort but is often more powerful than reactive research!
  • 20.
    © alpha2infinity VOC technique:listen LISTEN to Customers  Survey  Interviews  Focus Groups
  • 21.
    © alpha2infinity VOC technique:observe OBSERVE Customer behavior  Focus Groups  Go & See  Ethnography Studies
  • 22.
    © alpha2infinity affinity diagram 22 Theaffinity diagram is a tool used to organize ideas and language data. This method was developed by a noted Japanese anthropologist in the 1950s called Jiro Kawakita. He was confronted with a need to summarize large quantities of factual language data from his field research. He had an “aha” moment about grouping the data and distilling it into useful fundamental messages.
  • 23.
    © alpha2infinity voice(s) ofcustomer Normally my husband puts appliances together, but not this one. It was very easy to assemble the item. After meeting with the customers, write down one key customer insight that you heard or saw per Post-it Vote to select top 20
  • 24.
    © alpha2infinity affinity diagram Easeof Assembly Category 2 Category 4Category 3 Lone Wolf Group images into similar categories Work until ≤ 5 categories Category Titles are Drivers in CTQ tree
  • 25.
    © alpha2infinity agenda 25 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements • Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 26.
    © alpha2infinity critical toquality 26 A CTQ (critical-to-quality) is a specific measurable characteristic of a product or service that fulfils the expressed requirement of the customer. CTQ performance must exceed specifications to satisfy the customer. Hard to measure Easy to measure Need Drivers CTQs Specification Rich 1.1 < TDS > 1.3 Not Acidic Extraction > 18% Not Bitter Extraction < 22% > 140°F < 176°F Price < $1.99 / medium Taste Temperature Cost Customer wants "good coffee" Optimum drinking temperature We need to translate VOC to CTQs
  • 27.
    © alpha2infinity CTQ tree 27 •Only 1 CTQ / Project • Cannot improve Project CTQ at expense of other CTQs Cannot rob Peter to pay Paul
  • 28.
    © alpha2infinity agenda 28 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders • Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 29.
    © alpha2infinity stakeholders Stakeholder: Anyone impactedby your projectTeachers Principal Team Members You Stakeholders can be inside & outside the organization
  • 30.
    © alpha2infinity why stakeholderanalysis? • Provide resources • Give advice • ‘lobby’ for your cause • Break down barriers • Accelerate and improve results • Withhold resources • Withhold expertise • Convince others to withhold support • Create barriers • Delay and sabotage
  • 31.
    © alpha2infinity stakeholder analysis Stakeholderanalysis is a critical because it influences: Resources, Solutions and ultimately Project success! So we need to be Proactive about identifying and managing Stake Holders
  • 32.
    © alpha2infinity agenda 32 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE • Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 33.
    © alpha2infinity before projectbegins Needs Approval & Sponsor Team
  • 34.
    © alpha2infinity project charter ProjectCharter is a good executive communication tool
  • 35.
    © alpha2infinity agenda 35 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone) • Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 36.
    © alpha2infinity measure phase 36 Measure Y= f(x1, x2, …, xn) Analyze Y = f(x1, x2, …, x9) Improve Y = f(x1, x2, x3) Control Define Project Y • Define project scope. Begin & End • Define Project Y. How will we measure success? • Ensure good Measurement System • Measure current performance • Map the process and identify ALL variables that can affect performance • Analyze existing process data • Identify significant process variables affecting performance • Experiment to determine set points of critical process inputs to control process • Implement new improved process • Demonstrate performance of new improved process • Develop plans to sustain improvement
  • 37.
    © alpha2infinity process mapping Everythingis a process. What is Process Mapping? Graphical illustration of the work process When do you apply process mapping? Always What are benefits of Process Mapping? Identify major tasks / activities that are performed Identify sequence of tasks / activities Identify accountability of task /activities Identify process inputs that affect process output Tools Required 1. Room with large wall 2. X-functional team (6 – 8) 3. Experts on the process 4. Sharpie Markers 5. Large colored Post-it Start with SIPOC Complete Flow chart Complete Process Map
  • 38.
    © alpha2infinity flowchart symbols Start/ Stop Action (verb / noun) Decision Y N Delay or Wait Documentation Or Paperwork Movement
  • 39.
    © alpha2infinity flowchart example StartDrive to Airport Park the Car Walk to Terminal Wait in Line Security Check Walk to Gate Wait for Boarding Stop ID Check e-ticket? bags?Walk to security Walk to Counter Print B. Pass Board Plane N Y N Check bags Wait in Line Wait in Line List + Sequence of Actions, Delays, Decisions and Movement
  • 40.
    © alpha2infinity Fishbone Originally developedby Prof. Kaoru Ishikawa to show the causes of a specific effect, this tool encourages the team to think of inputs in categories of: Personnel, Measurement, Environment, Material, Machine & Method (6Ms).
  • 41.
    © alpha2infinity fishbone 41 Fishbone Diagramis useful in identifying all inputs to a process step. Ideally, create a fishbone for every major process step
  • 42.
    © alpha2infinity process mapping 42 •List Inputs and Outputs for each Action Step • Goal is to identify ALL process inputs. • Some of these are the cause of undesired variation
  • 43.
    © alpha2infinity agenda 43 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs • Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 44.
    © alpha2infinity cause &effect matrix 44 Major process outputs & their importance Major process inputs Higher Scores are more important Collect data on Project Y & process inputs (Xs) for subsequent analysis
  • 45.
    © alpha2infinity agenda 45 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics • Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 46.
    © alpha2infinity types ofdata DATA Attribute Variable Binomial Data can have only 2 values • pass/fail, yes/no Poisson Data can have any discrete value • A+, A, A-, B+, B, B-,… F Data can have any value on continuous scale Normal t-distribution lognormal Weibull triangular uniform & many more! COUNT MEASURE
  • 47.
    © alpha2infinity sample vpopulation Population estimate Study the sample to make inferences about the population Sample mini-population
  • 48.
    © alpha2infinity common statistics DATA AttributeVariable Location • mean • median • mode Spread • range • standard deviation • variance Shape • skewness • kurtosis Counts (Poisson) Proportions (binomial)
  • 49.
    © alpha2infinity location Mean: thetotal of values divided by the number of values; • (2 + 1 + 2 + 3 + 4 + 5) / 6 = 2.83 • Is sensitive to extreme scores Median: the middle value after a set of values has been sorted (low to high) • 1, 2, 2, 3, 4, 5; the median is 2.5 • Is robust to extreme scores Mode: the value that occurs most frequently; • 1, 2, 2, 3, 4, 5; the mode is 2 • A data set may contain multiple modes; multimodal Consider a sample: 2, 1, 2, 3, 4, 5
  • 50.
    © alpha2infinity spread Range: maxvalue – min value • Range = 5 -1 = 4 • Is a poor estimator of variation; relies only on extreme values; ignoring most values Standard Deviation: the average distance of a data point from the mean • Most commonly used; has same units as the mean • Average distance from the mean • Less sensitive to outliers than the range Variance: (standard deviation)2 Consider a sample: 2, 1, 2, 3, 4, 5
  • 51.
    © alpha2infinity normal distribution Manynatural phenomena and man-made processes follow a “normal” distribution. It is a continuous distribution and can be described by its mean and standard deviation. Different Mean Same Standard Deviation Same Mean Different Standard Deviation
  • 52.
    © alpha2infinity shape Positive Negative SKEWNESS symmetry PlatykurticLeptokurtic KURTOSIS ‘peakedness’ Mean Median Mode
  • 53.
    © alpha2infinity property ofnormal distribution The area under the normal curve can be used to estimate the probability of an “event” occurring. If data is NOT normal (i.e. misshapen), these probabilities change. 3210-1-2-3 0.4 0.3 0.2 0.1 0.0 X Density 95% 99.73% 68% Ordinary UnusualUnusual
  • 54.
    © alpha2infinity normality check 54 Ifprobability of observing normality test statistic > 5%, data is normal
  • 55.
  • 56.
    © alpha2infinity agenda 56 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good • Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 57.
    © alpha2infinity why evaluatemeasurement system? 57 Observed Variation Variation from Process Variation from Measurement Due to Gage - accuracy Due to Operator - precision Need to ensure that at least 90% of what we are observing is from process. 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑜𝑏𝑠𝑒𝑟𝑣𝑒𝑑 = 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 + 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡 Repeatability Reproducibility
  • 58.
    © alpha2infinity accuracy &precision 58 Measurement quality is described by accuracy & precision Accuracy = Average value from target Calibration Study Precision = Variation amongst data points Gage R&R Study
  • 59.
    © alpha2infinity repeatability 59 Repeatability =agreement with self (attribute data) variation from one operator (variable data) Good Repeatability 1 3 2 Poor Repeatability 1 3 2 Test Conditions - same part - same gage - same operator 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡 = 𝑽𝒂𝒓𝒊𝒂𝒕𝒊𝒐𝒏 𝒓𝒆𝒑𝒆𝒂𝒕𝒂𝒃𝒊𝒍𝒊𝒕𝒚 + 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑟𝑒𝑝𝑟𝑜𝑑𝑢𝑐𝑖𝑏𝑖𝑙𝑖𝑡𝑦
  • 60.
    © alpha2infinity reproducibility 60 Jerry Bob Mike Good Reproducibility Bob Mike Jerry PoorReproducibility Reproducibility = agreement between operators (attribute data) variation from different operators (variable data) Test Conditions - same part - same gage - different operators 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡 = 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 𝑟𝑒𝑝𝑒𝑎𝑡𝑎𝑏𝑖𝑙𝑖𝑡𝑦 + 𝑽𝒂𝒓𝒊𝒂𝒕𝒊𝒐𝒏 𝒓𝒆𝒑𝒓𝒐𝒅𝒖𝒄𝒊𝒃𝒊𝒍𝒊𝒕𝒚 Measurement System Analysis should be performed for all Process CTQs (outputs of customer value)
  • 61.
    © alpha2infinity gage R&Rattribute data 61 70% 90% Kappa
  • 62.
    © alpha2infinity gage R&Rvariable data 62 28% 14% %GRR
  • 63.
    © alpha2infinity agenda 63 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE • Conduct Hypothesis Tests • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 64.
    © alpha2infinity capability 64 Capability Studiesdetermine process performance from the point of view of the customer! Voice of The Process Voice of The Customer 1USLLSL Specifications From Customer 𝐶𝑎𝑝𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝐶𝑝 = 𝑉𝑂𝐶 (𝑇𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒) 𝑉𝑂𝑃 (𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝑆𝑝𝑟𝑒𝑎𝑑) = (𝑈𝑆𝐿 − 𝐿𝑆𝐿) 𝟔𝜎 99.73%
  • 65.
    © alpha2infinity capability concept 65 TOLERANCE PROCESS TOLERANCE PROC. Capability= 1 3210-1-2-3 0.4 0.3 0.2 0.1 0.0 Capability = 2 3210-1-2-3 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 Cpk is a metric used to measure process capability
  • 66.
    © alpha2infinity capability metric,Cpk 66 𝐶𝑝𝑘 = 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑓𝑟𝑜𝑚 𝑋 𝑡𝑜 𝑛𝑒𝑎𝑟𝑒𝑠𝑡 𝑠𝑝𝑒𝑐 3𝜎 𝐶𝑝𝑘 = 𝑀𝑖𝑛 𝐶 𝑝𝐿, 𝐶 𝑝𝑈 𝐶 𝑝𝐿 = 𝑋 − 𝐿𝑆𝐿 3𝜎 𝐶 𝑝𝑈 = 𝑈𝑆𝐿 − 𝑋 3𝜎 Variable Data Attribute Data 𝐶𝑝𝑘 = 𝑃𝑟𝑜𝑝𝑜𝑟𝑡𝑖𝑜𝑛 𝑂𝑢𝑡𝑠𝑖𝑑𝑒 𝑠𝑝𝑒𝑐 0.20 0.15 0.10 0.05 0.00 Probability 11 0.01147 0 𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑅𝑎𝑡𝑒 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝐹𝑎𝑖𝑙𝑒𝑑 𝑁𝑢𝑚𝑏𝑒𝑟 𝐼𝑛𝑠𝑝𝑒𝑐𝑡𝑒𝑑 The failure rate can be converted to Cpk Customer Requirement Specification Capability Study should be performed for all Process CTQs
  • 67.
    © alpha2infinity capability calculation 67 Cpkfor Attribute Data 1.3 2.0 Cpk Cpk of 2 is 6 sigma process 3.4 defects in 1,000,000 Cpk for Variable Data
  • 68.
    © alpha2infinity analyze phase 68 Measure Y= f(x1, x2, …, xn) Analyze Y = f(x1, x2, …, x9) Improve Y = f(x1, x2, x3) Control Define Project Y • Define project scope. Begin & End • Define Project Y. How will we measure success? • Ensure good Measurement System • Measure current performance • Map the process and identify ALL variables that can affect performance • Analyze existing process data using appropriate hypothesis test • Identify significant process inputs • Experiment to determine set points of critical process inputs to control process • Implement new improved process • Demonstrate performance of new improved process • Develop plans to sustain improvement
  • 69.
    © alpha2infinity agenda 69 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests • Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 70.
    © alpha2infinity hypothesis testing 70 OurDecision X has NO effect on Y X has an effect on YTheAbsoluteTruth XhasNO effectonY  a error Seeing something not present Xhasan effectonY b error Miss seeing something that is present  In the measure phase, we identified all ‘potential’ causes of problem. In analyze phase we will examine data to identify the ‘significant’ causes.
  • 71.
    © alpha2infinity hypothesis testselection 71 SingleY Single X Attribute Variable Attribute Chi2 Logistic Regression Variable t-test ANOVA Medians Linear Regression 1. Based on data type select the correct Hypothesis test 2. All Hypothesis tests calculate the probability of a error and report it as p-value. 3. IF p-value is < 0.05, we are at least 95% confident that the X has a significant effect on Y
  • 72.
    © alpha2infinity scenarios 72 Is therea difference in burrito size between Chipotle & Moe’s? Parameter Description Type of Data Y X Hypothesis Test Weight of Burrito Variable Burrito Shop Attribute ANOVA (t-test) Does the age of male customer affect the type of car they buy? Parameter Description Type of Data Y X Hypothesis Test Type of Car Attribute Age Variable Logistic Regression
  • 73.
    © alpha2infinity scenarios 73 Does theair pressure effect how far TB12 can throw a football? Parameter Description Type of Data Y X Hypothesis Test Distance Thrown Variable Air Pressure Variable Regression Parameter Description Type of Data Y X Hypothesis Test Hire: yes, no Attribute Age: young, old Attribute Chi-Square The HR department wants to see if there is a link between age (old and young) and whether that person gets hired
  • 74.
    © alpha2infinity agenda 74 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square • t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 75.
    © alpha2infinity chi2 test -Enter Data - Evaluate p-value - Make Conclusion
  • 76.
    © alpha2infinity agenda 76 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 77.
    © alpha2infinity t-test 77 Use tocompare means of TWO groups
  • 78.
    © alpha2infinity mann-whitney test 78 Whendata is NOT normal, compare medians.
  • 79.
    © alpha2infinity between ANOVA 79 𝑊𝑖𝑡ℎ𝑖𝑛 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛= 𝑋𝑖 − 𝑋𝑖𝑗 2 𝐵𝑒𝑡𝑤𝑒𝑒𝑛 𝑉𝑎𝑟𝑖𝑎𝑡𝑖𝑜𝑛 = 𝑋𝑖 − 𝑋 2 𝐹 = 𝐵𝑒𝑡𝑤𝑒𝑒𝑛 𝑊𝑖𝑡ℎ𝑖𝑛 = 𝑆𝑖𝑔𝑛𝑎𝑙 𝑁𝑜𝑖𝑠𝑒 is F = 1? X2 𝑟1 𝑟2 𝑟3 X1 𝑏3 𝑏2 𝑏1 between Called ANalysis Of VAriance, but we make conclusions about Means
  • 80.
    © alpha2infinity ANOVA 80 Use todetermine if means of > TWO groups are all equal
  • 81.
    © alpha2infinity mood’s mediantest 81 When data is NOT normal, analyze medians.
  • 82.
    © alpha2infinity agenda 82 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 83.
    © alpha2infinity Regression 83 Variation inY explained by Model 1. Is there a linear relationship between X and Y? 2. Can the X predict the Y value?? i.e Equation 3. & if yes, how good is this prediction???
  • 84.
    © alpha2infinity improve phase 84 Measure Y= f(x1, x2, …, xn) Analyze Y = f(x1, x2, …, x9) Improve Y = f(x1, x2, x3) Control Define Project Y • Define project scope. Begin & End • Define Project Y. How will we measure success? • Ensure good Measurement System • Measure current performance • Map the process and identify ALL variables that can affect performance • Analyze existing process data using appropriate hypothesis test • Identify significant process inputs • Experiment to determine set points of critical process inputs to control process • Implement new improved process • Demonstrate performance of new improved process • Develop plans to sustain improvement
  • 85.
    © alpha2infinity agenda 85 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE  Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 86.
    © alpha2infinity DOE 86 In theANALYZE phase we looked at existing data. In the IMPROVE phase, we conduct experiments using a systematic method to determine cause-and-effect relationships between inputs into a process (factors) and the output of that process (response). Process Inputs (Factors) – Change brand of gas  Octane rating (85, 90)  Driving Speed (55, 60) – Tune-up Car – New tires  Tire Pressure (30, 35)  Significant Inputs identified in analyze phase Process Output (Response) – Fuel efficiency Specification: > 30 mpg Driving (Process)
  • 87.
    © alpha2infinity DOE setup 87 -Enter set points of factors to setup experimental conditions - Enter response values of experimental runs
  • 88.
    © alpha2infinity DOE 88 - Evaluatep-value to identify critical factor(s) - Determine contribution of each factor (practical)
  • 89.
    © alpha2infinity agenda 89 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE  Design of Experiments  Brainstorming • Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 90.
    © alpha2infinity brainstorming 90 Brainstorming is atool for generating as many ideas or solutions to a problem. Ideas should be as broad and wide as possible. There are no bad ideas. However it is not a tool for determining the best solution to the problem. Brainstorming should be done with a team
  • 91.
    © alpha2infinity brainstorming Methods 91 Free-wheelingbrainstorm: • Team members call out their ideas spontaneously. • The scribe records the ideas as they are suggested. Round-robin brainstorming: • The facilitator asks each member, in turn, for an idea. • Members may pass on any round. • The facilitator records the ideas. The session continues until team members have no more ideas to add. The slip method: • The facilitator asks members to write down their ideas on Post-its. • Post-its are placed on wall for everyone to read. • Allow team to write new ideas after reading the Post-its • All ideas are then collected and organized (No duplication, Clarity). 
  • 92.
    © alpha2infinity agenda 92 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE  Design of Experiments  Brainstorming  Idea Box • Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 93.
    © alpha2infinity ideabox 93 Idea Boxis a creativity technique based on concepts (morphological analysis) developed by Fritz Zwicky a Swiss astrophysicist in the 1940's. 1. Write down the problem statement 2. Break down the problem into smaller elements (think SIPOC) 3. Lists options for each element 4. Pick options that combine into ‘best’ solution
  • 94.
    © alpha2infinity ideabox This techniqueresults in many permutations The art lies in picking the best combination to solve the problem
  • 95.
    © alpha2infinity agenda 95 DEFINE  Identifythe vital few  Bound the problem  Understand customer requirements  Prioritize customer requirements  Identify project stakeholders  Complete Project Charter MEASURE  Map the process (Fishbone)  Prioritize process inputs  Basic Statistics  Verify measurement system is good  Determine current process capability ANALYZE  Conduct Hypothesis Tests  Chi Square  t-Test & ANOVA  Linear Regression IMPROVE  Design of Experiments  Brainstorming  Idea Box  Solution Selection CONTROL • Demonstrate improvement • Operating Instructions • Develop control plan • Monitor new process
  • 96.
    © alpha2infinity selecting asolution 96 Quality S1 S2 S3 S4 Mary 1 2 3 4 Peter 2 1 3 4 Priya 1 2 3 4 Chelsea 1 2 3 4 TOTAL 5 7 12 16 Each person ranks Each solution against Each criteria. The total score is entered into the matrix and solutions are ranked from best
  • 97.
    © alpha2infinity agenda 97 DEFINE • Paretoof problems • Bounding the problem • KANO & ‘Voice of Customer’ • Why talk to all customers? • Project Charter MEASURE • Process Mapping • Fishbone • Basic Statistics • Measurement System Analysis • Capability ANALYZE • Hypothesis Testing • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL  Demonstrate improvement • Write Instructions • Develop control plan • Monitor new process
  • 98.
    © alpha2infinity B vC comparison 98 Analyze data from old & new process Evaluate if 1. New process is better? (t-test) 2. Is it good enough? (new Cpk)
  • 99.
    © alpha2infinity agenda 99 DEFINE • Paretoof problems • Bounding the problem • KANO & ‘Voice of Customer’ • Why talk to all customers? • Project Charter MEASURE • Process Mapping • Fishbone • Basic Statistics • Measurement System Analysis • Capability ANALYZE • Hypothesis Testing • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL  Demonstrate improvement  Write Instructions • Develop control plan • Monitor new process
  • 100.
    © alpha2infinity examples ofSOP 100 Too Wordy Succinct, Multi-Lingual, Minimal Reading
  • 101.
    © alpha2infinity101 List inputs, required operations& expected outputs for each process step
  • 102.
    © alpha2infinity agenda 102 DEFINE • Paretoof problems • Bounding the problem • KANO & ‘Voice of Customer’ • Why talk to all customers? • Project Charter MEASURE • Process Mapping • Fishbone • Basic Statistics • Measurement System Analysis • Capability ANALYZE • Hypothesis Testing • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL  Demonstrate improvement  Write Instructions  Develop control plan • Monitor new process
  • 103.
    © alpha2infinity control plan 103 Completeall sections of control plan, particularly - current controls & - reaction plans for key process outputs
  • 104.
    © alpha2infinity agenda 104 DEFINE • Paretoof problems • Bounding the problem • KANO & ‘Voice of Customer’ • Why talk to all customers? • Project Charter MEASURE • Process Mapping • Fishbone • Basic Statistics • Measurement System Analysis • Capability ANALYZE • Hypothesis Testing • Chi Square • ANOVA • Linear Regression IMPROVE • Design of Experiments • Brainstorming • Idea Box • Solution Selection CONTROL  Demonstrate improvement  Write Instructions  Develop control plan  Monitor new process
  • 105.
    © alpha2infinity control chart 105 Investigateroot cause of any out-of-control incident.
  • 106.
    © alpha2infinity pre-control chart 106 Runin green zone, Reset in red zone, Investigate if in between
  • 107.