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05. Process Mapping tools for 6 sigma.ppt
- 2. Seagate Confidential 2 Supplier Six Sigma Modular Training Process Mapping Learning Objectives Overview of a Process Map Benefits of Process Mapping Learn how to build a Process Map, step by step Difference between Top Level Map & a Detail Map Learn how Process Mapping fits into process improvement activities Complete a Process Mapping Exercise Learn how to integrate Process Mapping into your Company SOPs
- 3. Seagate Confidential 3 Supplier Six Sigma Modular Training Process Mapping What is a Process Map? Is a graphical representation of the flow of a process It contains information that is beneficial to improving the process It represents the process as it actually exists
- 4. Seagate Confidential 4 Supplier Six Sigma Modular Training Process Mapping No Yes Customer places order Is order Correct? Send order to Warehouse for picking Is product Available? Pick product for order Does customer have Other shipments? Ship order Customer receive order Will customer allow Consolidated shipments? Consolidated orders Will product Be available Before order ships? Is production schedule To manufacture Product? Can production Manufacture Product in time For shipping? Will customer Accept back Order? Cancel order Expedite manufacturing schedule Place order on hold Until product available Call customer and Make corrections Yes No Yes No Yes Yes No No Yes Yes No No Yes No Typical Order Fulfillment Process Sales OrderEntry Warehousing Transportation Example of a Process Map
- 5. Seagate Confidential 5 Supplier Six Sigma Modular Training Process Mapping Key Elements of a Process Map Should Describe: Major activities/tasks Sub-processes Process Boundaries (top level vs. detail) Process Inputs X’s Process outputs Y’s Process step outputs y’s Should be reviewed frequently and updated y f x x xk ( , ,..., ) 1 2
- 6. Seagate Confidential 6 Supplier Six Sigma Modular Training Process Mapping Benefits of Process Mapping Reveals “Hidden Factories” Exposes inaccurate assumptions, beliefs, and understandings Enables rigorous, thorough examination of the outputs and inputs Increases probability of capturing all the y’s and x’s Increases probability of getting to y = f(x). Identification of outputs needing measurement studies Identification of outputs for capability studies Opportunities for elimination of non-value-added steps or addition of needed steps Can provide a snapshot for future comparisons
- 7. Seagate Confidential 7 Supplier Six Sigma Modular Training Process Mapping Building a Process Map What is a work process? INPUT OUTPUT PROCESS Transformation (Value-Added) Steps
- 8. Seagate Confidential 8 Supplier Six Sigma Modular Training Process Mapping Determine scope of the process as it relates to the project/product Large, cross-functional processes that involve many people are called macro processes. Executives tend to view the organization in this manner. Smaller, local processes are called micro processes. This is the view of line employees and first line management. The scope of the process must be defined at an actionable level. * Building a Process Map Process Scope Select Right Team Map: Primary Process Alternative Paths Inspection Points Use Map to Improve Process
- 9. Seagate Confidential 9 Supplier Six Sigma Modular Training Process Mapping Team Formation Manufacturing Engineers ME Technicians Design Engineering Line Operators Line Supervisors Maintenance Technicians * Building a Process Map Process Scope Select Right Team Map: Primary Process Alternative Paths Inspection Points Use Map to Improve Process
- 10. Seagate Confidential 10 Supplier Six Sigma Modular Training Process Mapping Building a Process Map Process Scope Select Right Team Map: Primary Process Alternative Paths Inspection Points Use Map to Improve Process KEY PROCESS INPUT VARIABLES KEY PROCESS OUTPUT VARIABLES X’s MANAGE Y’s CORRECT, IN-SPEC KPIV KPIV KPIV PROCESS VALUE-ADDED STEPS KPOV KPOV DEFECT-FREE CTQ
- 11. Seagate Confidential 11 Supplier Six Sigma Modular Training Process Mapping Process Flow Symbols OPERATION All steps in the process where the object undergoes a change in form or condition. TRANSPORTATION All steps in a process where the object moves from one location to another, outside of the Operation STORAGE All steps in the process where the object remains at rest, in a semi-permanent or storage condition DELAY All incidences where the object stops or waits on a an operation, transportation, or inspection INSPECTION All steps in the process where the objects are checked for completeness, quality, outside of the Operation. DECISION
- 12. Seagate Confidential 12 Supplier Six Sigma Modular Training Process Mapping Dryer Body Assembly INPUTS OUTPUTS (Big Y’s) Assembly Labor Procedures Materials Equipment, Fixtures Environment Cleanliness Rework Part to Print Performance to Spec Visually acceptable Leak free Identified Clean Packaged for use Consistent standard Develop an Upper Level Process Map Identify Major Inputs and Customer Outputs for the Suspect Process Identify Possible Connections
- 13. Seagate Confidential 13 Supplier Six Sigma Modular Training Process Mapping Identify Process Steps Within Boundaries Label Body 2 Insert Spirol Pin 3 Assemble Pistons 4 Assemble Cover 5 Dryer Paperwork 1 Test 6 Why is one of the steps a diamond? 7 Store Dryer Body Assembly
- 14. Seagate Confidential 14 Supplier Six Sigma Modular Training Process Mapping Map Inspection Points Signaled by a decision diamond Decision diamonds must pose a question -- no exceptions -- remains consistent with Mapping Alternative Paths. An inspection point creates a pass or fail decision based on objective standards Inspections may lead to a reversal of process flow direction, rework loop or a scrap. Specific, objective questions are almost always better. 6 Test Is the pin seated correctly? Does the O ring function properly? Is the cover aligned correctly?
- 15. Seagate Confidential 15 Supplier Six Sigma Modular Training Process Mapping List Output Variables (little y’s) for Each Step Is the pin seated correctly? Does the O ring function properly? Is the cover aligned correctly? How do little y’s relate to big Y’s? What if they don’t? 2 Insert Spirol Pin 3 Assemble Pistons 4 Assemble Cover 5 Dryer Body Assembly Paperwork 1 Route Ticket Orientation Label adhesion Greased O ring Screw position adj. Flush w/ surface Label Body O ring position Cover orientation Snap ring inserted Functional Assembly Rework Test 6 7 Store
- 16. Seagate Confidential 16 Supplier Six Sigma Modular Training Process Mapping List Inputs (x’s) for each Process Step 2 Insert Spirol Pin 3 Assemble Pistons 4 Assemble Cover 5 Dryer Body Assembly Paperwork 1 7 Route Ticket Orientation Label adhesion Greased O ring Screw position adj. Flush w/ surface Label Body O ring position Cover orientation Snap ring inserted Stores Functional Assembly Rework Bills of materials ISO Procedures Cleanliness Material Press Force Material Assy Technique Amount of Grease Material Assy technique Adjustment Pos. Snap Ring Insertion Material Test Capability Calibration Test 6 Is the pin seated correctly? Does the O ring function properly? Is the cover aligned correctly? How do the x’s relate to big Y’s and small y’s? 7 Store
- 17. Seagate Confidential 17 Supplier Six Sigma Modular Training Process Mapping Versions of a Process What You Think It Is... What It Actually Is... What You Would Like... AT LEAST THREE
- 18. Seagate Confidential 18 Supplier Six Sigma Modular Training Process Mapping Manufacturing Variation Causes A "Hidden Factory" Increased Cost - Lost Capacity The process map reveals this hidden factory Yield After Inspection or Test Each defect must be detected, repaired and placed back in the process. Each defect costs time and money. Scrap Rework Hidden Factory NOT OK Operation Inputs Inspect First Time Yield OK • Wasted Time • Wasted Money • Wasted Resources • Wasted Floor space 90% Customer Quality Defects and the Hidden Factory
- 19. Seagate Confidential 19 Supplier Six Sigma Modular Training Process Mapping Add the operating specifications and process targets for the Controllable and Critical Inputs (if available) X Critical N Noise S SOP C Controllable 2 Insert Spirol Pin 3 Assemble Pistons 4 Assemble Cover 5 Paperwork 1 Route Ticket Orientation Label adhesion Greased O ring Screw position adj. Flush w/ surface Label Body O ring position Cover orientation Snap ring inserted Functional Assembly Rework Dryer Body Assembly Test 6 Is the pin seated correctly? Does the O ring function properly? Is the cover aligned correctly? S Bills of materials S ISO Procedures S Cleanliness C Material X Press Force C Material S Assy Technique C Amount of Grease C Material S Assy technique N Adjustment Pos. C Snap Ring C Insertion C Material X Test Capability S Calibration 7 Store Controllable Input Variable Target Upper Spec Lower Spec Press Force 10 lbs 12 lbs 8 lbs Amount of Grease 2 cc's 1.5 cc's 2.5 cc's Adj Pos'n 3 turns 3.5 turns 2.5 turns
- 20. Seagate Confidential 20 Supplier Six Sigma Modular Training Process Mapping A process map which accurately and completely describes the process is important because it serves as input to: – Fishbone Diagram – the Cause and Effects Matrix – the FMEA – the Control Plan Summary – the Capability Summary – Multi-vari studies – Rolled Throughput Yield How Process mapping can Fit into Process Improvement Activities Process Scope Select Right Team Map: Primary Process Alternative Paths Inspection Points Use Map to Improve Process
- 21. Seagate Confidential 21 Supplier Six Sigma Modular Training Process Mapping How Process mapping can Fit into Process Improvement Activities Process Map 6 3 138 16 Catalyst Stripper Pluggage 3 6 5 3 137 111 Drying Decomposition 2 6 3 2 2 134 39 Drier Water Carryover 4 6 5 1 132 34 Drier Molecular Sieve 3 3 2 7 2 125 Cause and Effects Matrix Process Step/Part Number Potential Failure Mode Potential Failure Effects S E V Potential Causes O C C Current Controls D E T RPN Actions Recommended Resp. FMEA Initial Assessment of Capabilities and Control Plans PAPERWORK TURN STEAM ON TO DICY TANK LOAD DMF LOAD DICY LOAD 2MI 1 BILL OF MATERIALS ISO PROCEDURES REWORK SCALE ACCURACY PREHEATING LOAD ACCURACY CLEANLINESS RAW MATERIAL LOAD ACCURACY ENVIRONMENT (HUMIDITY) RAW MATERIAL MIXER SPEED LOAD ACCURACY ENVIRONMENT (HUMIDITY) RAW MATERIAL MIXER SPEED 1 2 3 4 5 6 7 8 9 10 11 Process Step Process Inputs Heavies in Product Lights in Product Moisture in Product Acidity in Product Low Capacity From Unit Excessive Downtime Material Losses Corrosion of Equipment Poor Reactor Performance Total 139 Day TanksAnalysis 10 10 9 9 335 9 Reactor Cat./HF Ratio 5 8 7 157 7 Reactor Rxr Temperature 6 5 4 7 149 73 Lights Removal Condenser Leak 4 8 2 4 1 148 74 Lights Removal Reboiler Leak 4 8 2 4 1 148 131 PurificationLow Stages 8 8 144 144 Final Storage Containers 3 2 6 6 140 100 Neutralization pH Value 6 Process Step Input Output Process Specification (Target, LSL, USL) Cpk Mean - Sigma Measurement Technique %R&R P/T Sample Size Sample Frequency Control Method Reaction Plan Coating Dosage 22.5, 22, 23 1.22 UIL-1700 25% 1/hr Auto-timer Cross check Coating Height 24,23,25 1.54 Micrometer 31%/0.4735 pts per panel 1/hr Coating & pump speed Adjust previous Coating width 14,12,16 1.78 Laser Measuring Device 1/hr None in place Coating length 36,34,38 1.43 Laser Measuring Device 1/hr None in place Vacuum 35" Hg Vacuum Gauge 1/hr Monitor Compare guages, look for blockage COATING & IMAGING DIRTY PHOTOMASK MICROCRACKING, DELAMINATION, STREAKS 8 LOW FREQUENCY OF CLEANING 8 SOP, VISUAL INSPECTION 7 448 INCREASE FREQUENCY TO ONCE EVERY 20 PANELS MG IMPROVE CLEANING METHOD PF PURCHASE OFF-LINE CLEANING SYSTEM MG TEST ON-LINE MASK REPLACEMENT PF The Big Picture
- 22. Seagate Confidential 22 Supplier Six Sigma Modular Training Process Mapping Integrating Process Mapping into SOPs Example: Process Mapping in First Article. SPQP and FA checklist to include Process Mapping SPQP and FA checklist to include Process Mapping Section of FA Procedure
- 23. Seagate Confidential 23 Supplier Six Sigma Modular Training Process Mapping Customer triggers SCAR Suppliers identifies potential process steps where root causes may be found Process map of the process steps involved (Micro) Fishbone diagram to Brainstorm / identify root cause Further Actions Example: Process Mapping in SCAR Integrating Process Mapping into SOPs
- 24. Seagate Confidential 24 Supplier Six Sigma Modular Training Process Mapping Link Tools Integration Tasks to Work Breakdown Structure S/N Tasks Task Owner Target Completion Date Specific Training needed for Task Owner/ Date Core Team Member In Charge Internal Verified Date Group Phase End Date Group 1 Tools 1 FA 1.Integrate Process Mapping into FA procedure/system Nick 10-Dec-01 Process Mapping - 15-Nov-01 Yu 15-Dec-01 31-Dec-01 2. Incorporate Process Mapping in FA package 13-Dec-01 2 SCAR 1. Integrate Process Mapping into SCAR procedure/system James 10-Dec-01 Process Mapping - 15-Nov-01 William 15-Dec-01 31-Dec-01 The effort to integrate Process Mapping into FA and SCAR procedures should be translated into specific tasks in the Work Breakdown Structure.
- 25. Seagate Confidential 25 Supplier Six Sigma Modular Training Process Mapping Process Mapping Helpful Hints Always Process map with a team. Rarely, does one person have all process knowledge. Interrogate the process by watching in many different conditions. You must watch the process as it happens to see the detail you need. Maintain your Process Maps with dates and update them as necessary. Use them as a reference. When to update a Process map? Whenever a change is being considered to a product’s design, application, environment, material, or to a product’s manufacturing or assembly processes.
- 26. Seagate Confidential 26 Supplier Six Sigma Modular Training Process Mapping End of Topic Any question?
- 27. Seagate Confidential 27 Supplier Six Sigma Modular Training Process Mapping Reading Reference Basic Statistics Tools for Continuous Improvement, Mark J Kiemele, Stephen R Schmidt, Ronald J Berdine, Air Academy Press, ISBN 1-880156-06-7
- 28. Seagate Confidential 28 Supplier Six Sigma Modular Training Process Mapping Process Map Example: Athena Front End Mechanical Texture (45mins soak in piggy back) 1st Wash Double Scrub Oliver Kitting Laser Texture 2nd Wash Post Laser Oliver Wash Ultrafab Wash QC Optics (3disks / 3hrs) Pass? Sputter RMM, Raman, N&K (1disk/0.5hr) XRF (1disk/2hr) Pass? Lube WIP Backend Process WIP < 4hrs Ra / Line Density (1/200) Pass? Yes u/s wash, create AUT lot No repolish, adjust EDC QC Optics (3 discs / 3 hrs) Pass? Yes Rewash all samples Resample failure Down for Eng'rg/Maint on 2nd failure Phase Shift (1/200 discs) Pass? Fail - repolished, resample Down for Eng'rg/ Maint on 2nd failure No WIP <= 3 hrs? Yes No Yes Yes No Rewash all samples Resample failure Down for Eng'rg/Maint on 2nd failure No Yes No Fail - carbon strip Resample failure Down for Eng'rg/Maint on 2nd failure
- 29. Seagate Confidential 29 Supplier Six Sigma Modular Training Process Mapping 6s Project Filename Author Date Process Map Overview PRIME FLOW ( Modular Cell ) Pallet Unload Modular Merge Flex/Filter Install PASS ? Clamp Ring Install Disc Stack Pallet Load RVA (Sampling) Balance Verify Balance Correct Balance Check Top Cover Install DAC (Sampling) Loading of Components / Inspection Return Conveyor (Pallets) Yes DEBUG No Test Area Sub- Assembly Reruns Reruns Rework Hidden Factory !!! Appendix 1