PE Playbook - Process Excellence
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PE is a structured approach consisting of 5 phases to improve current process (DMAI2C) or to design new process (DMADV2) in a controlled efficient way.
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PE Playbook - Process Excellence
- 1. Copyright 2016 Gisoco 13/10/2016 1 SIPOC Affinity Diagram Cause-and-Effect Diagram Control Chart CTQ Tree Design of Experiments (DoE) VOCTRIZ Stratification Stakeholder Analysis Quality Control ProcessChart Pugh Matrix Prototyping Project Charter Process Sigma Prioritization Matrix Pareto Chart MGP Mind Map Lessons Learned Kano Model In-and-Out-of-Scope Tool HOQ Gage R&R study FTA Frequency Plot FMEA Flow Diagram Five Whys Design Scorecards PE PLAYBOOK
- 2. Copyright 2016 Gisoco Who am I? • Enterprise architect • My passion, give to your business value, efficiency and vision • Previous work experience: CEO outdoor sports events company, SAP consultant, 16 years Johnson & Johnson • PE black belt six sigma certified • PMP • I love to combine sports and the sunrise • https://twitter.com/Sgielen1 • https://fr.linkedin.com/in/sonjagielen • http://www.gisoco.com 13/10/2016 2
- 3. Copyright 2016 Gisoco 13/10/2016 3 SIPOC Affinity Diagram Cause-and-Effect Diagram Control Chart CTQ Tree Design of Experiments (DoE) VOCTRIZ Stratification Stakeholder Analysis Quality Control Process Chart Pugh Matrix Prototyping Project Charter Process Sigma Prioritization Matrix Pareto Chart MGP Mind Map Lessons Learned Kano Model In-and-Out-of-Scope Tool HOQ Gage R&R study FTA Frequency Plot FMEA Flow Diagram Five Whys Design Scorecards
- 4. Copyright 2016 Gisoco 13/10/2016 4 Lean ✔ ️ ✔ ️ Agree what customer really wants Understand your process ✔ ️ Smooth the flow ✔ ️ Shift from push to pull ✔ ️ Continue to attack waste Measure Process Exists?Define Measure Analyze Analyze Design Innovative Improvement Verify Validate Control Yes No PE is a structured approach consisting of 5 phases to improve current process (DMAI2C) or to design new process (DMADV2) in a controlled efficient way. Process Excellence (PE)
- 5. Copyright 2016 Gisoco • PE o Project Charter o Stakeholder Analysis o SIPOC o VOC § Affinity Diagram § Kano Model § CTQ Tree • DEX oProject Charter oMulti-Generation Plan (MGP) oIn-and-Out-of-Scope Tool oStakeholder Analysis 13/10/2016 5 Phase 1 - DefineMeasure Proces s Exists? Define Measure Analyze Analyze Design Innovative Improvement Verify Validate Control Yes No
- 6. Copyright 2016 Gisoco • PE o Prioritization matrix o FMEA o Stratification o Gage R&R study o Plots § Frequency Plot § Pareto Chart § Control Chart o Process sigma • DEX oVOC § Affinity Diagram § Kano Model oHouse of Quality (HOQ) oDesign Scorecards 13/10/2016 6 Phase 2 - MeasureMeasure Proces s Exists? Define Measure Analyze Analyze Design Innovative Improvement Verify Validate Control Yes No
- 7. Copyright 2016 Gisoco • PE o Affinity Diagram o Five Whys o Cause-and-Effect Diagram o Flow Diagram o Plots § Frequency Plot § Pareto Chart § Control Chart o Design of Experiments (DoE) • DEX oConcept § Mind Map § TRIZ § Flow Diagram oFeasibility § Pugh matrix § FMEA § FTA 13/10/2016 7 Phase 3 - AnalyzeMeasure Proces s Exists? Define Measure Analyze Analyze Design Innovative Improvement Verify Validate Control Yes No
- 8. Copyright 2016 Gisoco • PE Innovative Improvement o Generate Solutions § Prioritizaton matrix o Pilot Solution based on data from § Design of Experiments § Flow Diagrams § FMEA § Stakeholder Analysis • DEX Design oPrototyping oDetailed Design Elements 13/10/2016 8 Phase 4Measure Proces s Exists? Define Measure Analyze Analyze Design Innovative Improvement Verify Validate Control Yes No
- 9. Copyright 2016 Gisoco • PE Control o Quality Control Process Chart o Control Chart o Lessons Learned • DEX Verify Validate oHardware/Software Validation oSoftware Testing oDesign Scorecards oPlots § Frequency Plot § Pareto Chart § Control Chart § Process sigma 13/10/2016 9 Phase 5Measure Proces s Exists? Define Measure Analyze Analyze Design Innovative Improvement Verify Validate Control Yes No
- 10. Copyright 2016 Gisoco 13/10/2016 10 Affinity Diagram Affinity Diagram organizes data Cluster / group the data in capabilities / needs Need Capability Capability Capability DMAI2C - DMADV2 Causes Causes Causes
- 11. Copyright 2016 Gisoco 13/10/2016 11 Cause-and-Effect Diagram DMAI2C - DMADV2 “fish bone” To focus a large number of causes Set priorities by marking the most likely causes Main Problem (Effect) CauseCauseCause Potential Causes
- 12. Copyright 2016 Gisoco 13/10/2016 12 Control Chart DMAI2C - DMADV2 UCL LCL Mean plus or minus 1.5 σ 0 10 20 30 40 50 60 70 80 90 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Chart Title 32.34 32.34 Mean = 44 Mean = 44 σ = 21.56153983
- 14. Copyright 2016 Gisoco Design of Experiments (DoE) To analyze cause-and-effect To experiment changes in the process “Trial and Error” • Identify the vital few causes or process bottlenecks to investigate • Modify variables • Plot the data and analyze the effect 13/10/2016 14 DMAI2C - DMADV2
- 15. Copyright 2016 Gisoco 13/10/2016 15 Design Scorecard DMAI2C - DMADV2 To track progress until target specifications are met Target a Target b …. CTQ x Target Specifications (HOQ room 6) CTQs (HOQ room 3)
- 16. Copyright 2016 Gisoco Detailed Design Elements • Service / Product • Value to the customer • Process • SIPOC, Activity Flow Diagrams, Focus on VA, Minimize failures • Information systems • IT data, integration, application and infrastruture architectures • Organization • Deployment Flow Diagram • Facilities • Equipment / Materials • Environment • Regulatory • Public opinion • Community • Environmental risks 13/10/2016 16 DMAI2C - DMADV2
- 18. Copyright 2016 Gisoco Flow Diagram • Basic flow diagram (see SIPOC) • To identify major process steps • Activity flow diagram • To identify loops, complexity • Deployment flow diagram • To identify organizational inefficiencies • Opportunity flow diagram • To identify Value Added – Non Value Added process steps (VA – NVA) 13/10/2016 18 DMAI2C - DMADV2 Start/End Decision Activity Groups/Departments/PeopleStart/End Decision Activity VA NVA
- 19. Copyright 2016 Gisoco 13/10/2016 19 FMEA DMAI2C - DMADV2 Process step Potential Failure Potential Effect Severity of Effect Potential Cause Cause Occurrence Current controls Cause Detection RPN Action x x.1 x.2 y y.1 Failure Mode and Effect Analysis RPN Risk Priority Number (RPN) Multiply the 3 rates Rate Severity – Occurrence – Detection: 1 Good 10 Bad
- 20. Copyright 2016 Gisoco 13/10/2016 20 Frequency Plot DMAI2C - DMADV2 How often different values occur 0 10 20 30 40 50 60 70 80 90 1 2 3 4 5 6 7 8 Histogram Dot Plot
- 21. Copyright 2016 Gisoco 13/10/2016 21 Fault Tree Analysis (FTA) DMAI2C - DMADV2 Undesired event Failure To identify the weak points in a design concept Failure Failure Basic failure, no lower level Failure with lack of information, no lower level OR AND FailureFailure Failure Failure
- 23. Copyright 2016 Gisoco 13/10/2016 23 House of Quality (HOQ) DMAI2C - DMADV2 Room 7 Correlation Customer Needs (WHAT) Room 1 Measures HOW Room 3 How important Score Room 6 Room 5 Target / Specifications Technical Evaluation Relationships Strong Moderate Weak Room 4 Room 2 Importance Customer Rating
- 25. Copyright 2016 Gisoco 13/10/2016 25 Kano Model Kano Model (Japanese expert Noriaki Kano) 3 categories of customer needs: Must be – More Is Better - Delighters Presence Customer Satisfaction Absent Fulfilled Dissatisfied Delighted Neutral Delighters More Is Better Must be DMAI2C - DMADV2
- 26. Copyright 2016 Gisoco Lessons Learned • What worked well? • What didn’t worked well? • Plan – Actual comparison 13/10/2016 26 DMAI2C - DMADV2
- 27. Copyright 2016 Gisoco 13/10/2016 27 Mind Map DMAI2C - DMADV2 Main idea Idea Idea Idea Idea IdeaIdea Idea
- 28. Copyright 2016 Gisoco 13/10/2016 28 Multi-Generation Plan (MGP) DMAI2C - DMADV2 Product / Services Technologies 0 – 2 Years 2 – 4 Years 4+ Years Product / Services Technologies Product / Services Technologies Vision
- 29. Copyright 2016 Gisoco 13/10/2016 29 Pareto ChartDMAI2C - DMADV2 Frequency or impact of data divided into categories 0 10 20 30 40 50 60 70 80 90 Product look Delivery Product function Invoice Customer service Complaints - Pareto chart Occurence Categories
- 30. Copyright 2016 Gisoco 13/10/2016 30 Prioritization / Pugh matrix DMAI2C - DMADV2 To prioritize, To help to focus Priority a b c .. 1.Process 2. URS 1.Output of the process / 2. Potential solutions 1 Delighted 3 Neutral 5 Must be 1 Not acceptable 3 Acceptable 5 Satisfactory
- 31. Copyright 2016 Gisoco 13/10/2016 31 Process sigma DMAI2C - DMADV2 Accuracy Rate (Yield) DPMO Process Sigma 69% 308,537 2 93% 66,807 3 99% 6,210 4 99,977% 233 5 99,9997% 3.4 6 Data Opportunities for defects 20 Defects 4 Results Failure Rate 0,2000 Accuracy Rate 0,8000 Sigma Level 0,8416 Long Term Sigma Level 2,3416 Example with Data from control chart:
- 32. Copyright 2016 Gisoco 32 Project Charter DMAI2C - DMADV2 Status Elements Scope Has the scope of the project increased or decreased? Timing Is the project currently scheduled to be completed on-time? Resources Is the project staffed with the appropriate resources? Issues Are the project issues being properly managed and resolved? Status Levels No significant issues/risks exist that could impact scope, schedule, or budget Issues/risks exists that could/may impact scope, schedule, or budget Milestones have/will be missed; risks/issues exist that will likely impact scope, schedule, or budget Stakeholders Status Scope Timing Resources Issues Problem Statement Project Goal & Scope KPIsTeam Lead Members Milestones & Deliverables Key Accomplishments
- 34. Copyright 2016 Gisoco 13/10/2016 34 Quality Control Process Chart Plan / Do “Plan Do Check Act” (PDCA) To ensure quality and everyone uses the new process properly Check Act Process Steps Indicators What to check Corrective Actions DMAI2C - DMADV2
- 35. Copyright 2016 Gisoco 13/10/2016 35 SIPOC SUPPLIERS INPUTS PROCESSES OUTPUTS CUSTOMERS start stop DMAI2C - DMADV2
- 36. Copyright 2016 Gisoco 13/10/2016 36 Stakeholder Analysis Influence is bubble size Involvement Resistance MIN MAX MAX The Stakeholders Analysis is a tool used to identify the stakeholders impacted to define the attitudes to encourage and analyze the stakeholders' communication needs Identify stakeholder group / individual Identify level of Involvement, Resistance, Influence Main interests / concerns Objectives Communication needs Use the prioritization graph to identify the stakeholders that are key for success DMAI2C - DMADV2
- 37. Copyright 2016 Gisoco Stratification Stratification • Divide data into groups • Typical groups are: • Who: persons, departments, organizations • What: machines, supplies, services, products • Where: physical locations • When: time, day, week 13/10/2016 37 DMAI2C - DMADV2
- 38. Copyright 2016 Gisoco 13/10/2016 38 TRIZ DMAI2C - DMADV2 A “knowledge base” model for generating innovative solutions Your knowledge Team knowledge Company knowledge Competitors industries knowledge Non-Competitors industries knowledge All other information Gartner Forrester …
- 39. Copyright 2016 Gisoco VOC Voice Of the Customer (VOC) is used to describe customers needs and their perceptions of your product or service. • Identify your customer • Collect information • Analyze information (Affinity Diagram, Kano Model) • Translate into Critical to Quality (CTQ tree) • Set specifications for CTQs 13/10/2016 39 DMAI2C - DMADV2