6Sigma六西格玛精益生产持续改善分析管理常用工具资料 03_Breakthr(创新).ppt

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1、The Breakthrough Strategy Champion Training1Six Sigma Champion Training ApplicationRTY COPQ CapacityDesignManufacturingAdministrativePhase I:MeasurementPhase II:AnalysisPhase III:ImprovementPhase IV:ControlCan you think of administrative,design,and manufacturing examples where Breakthrough Strategy

2、plans can be applied using the following metrics?Real World Examples2Six Sigma Champion Training Six Sigma Breakthrough Strategy PlanTo insure sources of variation in processes are identified and eliminated through well developed,documented,and executed process control plans.PurposeThis plan insures

3、 the highest quality product or service with the least amount of unplanned process or equipment downtime.Goal3Six Sigma Champion Training Four Phases and 10 Key ToolsMeasureAnalyzeImproveControl$Process Map&Metrics Cause&Effect Matrix Failure Mode&Effects Analysis Gage R&R Studies Capability Analysi

4、s Multi-Vari Analysis Cause&Effect Diagrams Design of Experiments Statistical Process Control-SPC Control Plans4Six Sigma Champion Training Phase I:Process MeasurementPhase II:Process AnalysisPhase III:Process ImprovementPhase IV:Process ControlCharacterizationOptimizationPhases of Breakthrough Stra

5、tegy5Six Sigma Champion Training Phase I:Process Measurement Identify KPIVs and KPOVs on Process Map/FMEA Establish Measurement System Capability Establish Process Capability BaselinePhase II:Process Analysis Update Process Map,FMEA,Control Plan&Capability Identify Critical Input Variables Analyze P

6、rocess data using Six Sigma Tools Phase III:Process Improvement Verify and optimize Critical Input Variables Identify and Test Proposed Solutions Implement Solutions and Confirm ResultsPhase IV:Process Control Enact Standardization/Mistake Proofing Implement Process Controls and Verify Effectiveness

7、 Monitor Process by Control Plan-HOLD the GAINSPhases of Breakthrough Strategy6Six Sigma Champion Training YMeasurementAnalysisImprovementControlDefine the Project (RTY,COPQ,increase Capacity)Map Process(List KPIVs/KPOVsEstablish Measurement System CapabilityPerform Short-Term CapabilityFMEA and Con

8、trol Plan ReviewIdentify Vital Few Variation SourcesIdentify and Prioritize KPIVs for Further StudyVerify Impact of KPIVsCritical Input Variables Identified?Modify Design?Enact standardization/Mistake ProofingImplement Process ControlsMonitor Process-HOLD the GAINSY YNNCapability OK?NOptimize Critic

9、al Input VariablesImplement Solutions and Confirm ResultsYNFinal Review OK?RedesignDocumentBreakthrough Strategy Plan7Six Sigma Champion Training Phase 0:Determine Continual Improvement Project Focus DeliverablesProject StatementProject selection justificationInterrelationship with Business Strategy

10、 Benefit if successfully completed i.e.Why do it8Six Sigma Champion Training Step 2Define/Analyze Process-Process Map&FMEA-Control Plan-Cause&Effect Matrix-Initial ranking of KPIVsStep 1Define project objectives,metrics,and resource requirements-Team charter/Problem Statement-Business metrics goals-

11、Customer requirementsStep 3Characterize Process-3 Level Pareto charts-Measurement study report-Capability study reportStep 4Establish Process Metrics-Vital Few Variation Sources-Cp,Ppk,Zst,Zlt,DPU,RTY Phase I:Process Measurement Deliverables9Six Sigma Champion Training Step 5Identify root causes of

12、variation -Cause&Effect Diagrams-Horizontal Root Cause Charts-Potential Critical KPIVs ListStep 6Analyze process data -Multi-vari Charts-Hypothesis Tests-SPC Charts-Correlation&Regression AnalysisPhase II:Process Analysis Deliverables10Six Sigma Champion Training Step 7Test and verify critical input

13、 variables using DOE-Prioritized list of KPIVs needing further study-Critical input variable list Step 8Optimize the process using DOE -Documented KPIVs operating limits-DOE reportsStep 9Identify,plan and test proposed solutions-List of solutions impacting KPOVs-Improvement plansStep 10Implement sol

14、utions and improvement plans-Documented improvement plan and actionsPhase III:Process Improvement Deliverables11Six Sigma Champion Training Step 12Identify opportunities for standardization/mistake proofing-List of system improvementsStep 11Develop detailed process control plan using FMEA-Process co

15、ntrol plan documentedStep 13Verify effectiveness of process controls and system improvements-Monitoring process plan documented-Long term capability study reportStep 14Document project-List of best practices and lessons learned-Project presentation-Final reportPhase IV:Process Control Deliverables12

16、Six Sigma Champion Training Process MapFailure Modes and Effects AnalysisStatistical Methods and DOEProcess Control Plans Process Procedures Total Preventive Maintenance Mistake Proofing Training SafetyProcess MeasurementProcess AnalysisProcess ImprovementProcess ControlBreakthrough Strategy Plan13S

17、ix Sigma Champion Training Safety requirements Maintenance plans defined System to track special causes Required and critical spare parts list Trouble shooting guidesSPC ChartsProcess monitorsInspection pointsMetrology controlControl PlansMaintenanceEngineeringOtherLabor RequirementsBreakthrough Str

18、ategy Plan Support Systems14Six Sigma Champion Training MeasureAnalyzeImproveControlSelect/Plan Project-Project justification-Define business metrics-Identify process-Identify team members-Bound the project/processIdentify Customer Requirements-CTQs via QFD,C&E Matrix-Identify additional data NeedsE

19、stablish Process Metrics-Calculate Cp,Ppk,Zst,Zlt-Calculate DPU,RTY-Business metrics goalsTrain Team on 6 sigma toolsCreate Product/Process TreeReview Measure Phase-Champion/MBB comments-Update team/stakeholdersTrain Team on 6 sigma toolsUpdate Project Baseline&Status-Update Process Map,FMEA,Control

20、 Plan-Update Business metrics goal and graphs-Update Project Status Form-Verify Capability Cp,Ppk,Zst,Zlt,DPU,RTY-Identify additional data Needs-Verify data collection process-List of containment actionsIdentify Root Causes of Variation-Cause&Effect Diagrams (Fishbone charts)-Horizontal Root Cause c

21、harts-Screen potential causes&identify critical input variablesCollect and Analyze Process Data-Graphical Analysis-Hypothesis Tests-SPC charts-Multi-Vari charts-Correlation&RegressionImplement Solutions-Identify improvement actions and implementation plan-Implement/validate/communicate improvements/

22、actions-Document improvement plan and actionsDevelop Presentation-Project Status Form/Timeline-Metric Graphs with goal line-Review with Team/Champion/MBBTrain Team on 6 sigma toolsDevelop Presentation-Project Status Form/Timeline-Metric Graphs with goal line-Final Report-Review with Team/Champion/MB

23、BReview Analyze Phase-Champion/MBB comments-Update team/stakeholdersReview Improve Phase-Champion/MBB comments-Update team/stakeholdersDevelop Presentation-Project Status Form/Timeline-Metric Graphs with goal line-Review with Team/Champion/MBBDevelop Presentation-Project Status Form/Timeline-Metric

24、Graphs with goal line-Review with Team/Champion/MBBCharacterize the Process-3 level Pareto/SPC charts-Identify vital few variation sources-Conduct Gage R&R studies-Establish process capability on business metrics/variation sourcesDefine/Analyze Process-Create Process Map-Develop process FMEA-Create

25、data collection process (identify on Process Map)-Identify KPIVs&KPOVs-Develop Control PlanTrain Team on 6 sigma tools10%20%30%40%50%60%70%80%90%100%Overall Project Completion Percentage 0%0%Update Project Status-Update Process Map,FMEA,Control Plan-Update Business metrics graphs-Update Project Stat

26、us Form-Verify Capability Cp,Ppk,Zst,Zlt,DPU,RTY-List of containment actionsOptimize the Process using DOE-Verify and optimize critical input variables-Identify&test proposed solutions-Select solutions&confirm results-Establish optimum operating requirements-List of input variables needing further a

27、nalysisUpdate Project Status-Update Process Map,FMEA,Control Plan-Update Business metrics graphs-Update Project Status Form-Verify Capability Cp,Ppk,Zst,Zlt,DPU,RTY-List of improvement/follow-up actionsSustain the Gains-Identify opportunities for standardization/mistake proofing-Enact system improve

28、ments-Verify results of system improvements-Implement process controls-Verify effectiveness of process controls-Finalize process control plan-Ongoing monitoring of process by control plan-List best practices and identify lessons learnedSix Sigma Project Scorecard15SummaryReviewed the steps of the Breakthrough Strategy PlanReviewed the tools used in the Breakthrough Strategy PlanReviewed the deliverables for each step of the Breakthrough Strategy PlanWhat we have learned:16Six Sigma Champion Training