Overview of NIATx & Process Improvement Process Improvement Overview and Basic Training 2008.
1 Tumolo’s Toolbox 7 Step Improvement Process. 2 Elements of process improvement and control Every...
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Transcript of 1 Tumolo’s Toolbox 7 Step Improvement Process. 2 Elements of process improvement and control Every...
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Tumolo’s Toolbox
7 Step Improvement Process
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Elements of process improvement and control
Every process has three (3) elements
1. The area of discovery Understanding the customer requirements and
developing the process to meet these requirements
2. The method of process control Assessing performance and variation
3. The element of improvement Problem solving and quality improvement
3
7 Step Improvement Process
Process Control
Process Improvement Opportunity or Problem Identification
4
Improvement or Problem
Other world
prayerclairvoyance
Inner self
real world
others
the ininnovationinsightinventioninspirationintuitioninstinct
gut feel
CopyImitationconsultationBenchmark
delegationnegotiationjust waitingpassing-the-buckconfusingfinger pointingtransferringrandom
trial-and-errorguessaccidentchanceluck
systematic
PDCA7 Steps
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PDCA 7 STEP 7 QC Tools
PLAN
DO
CHECK
ACT
1. Select a Theme
2. Collect Data
3. Analyze causes/opportunities
4. Plan and implement
solution / improvement
5. Evaluate effects
6. Standardize
7. Reflect on process
Check sheet, graph,Histogram, scatter diagram,Pareto diagram, cause-and-effect diagram,flowcharts
Flowcharts
Check sheet, graph,Histogram, scatter diagram,Pareto diagram, cause-and-effect diagram,run chart/control chart
Flowchart
(provides repetition) (provides process) (provides tools)
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7 Step improvement process
1. Select Theme
2. Collect Data
3. Analyze Causes
4. Plan Solution and Implement
5. Evaluate
6. Standardize
7. Reflect on Process
• Focus on weakness
• Thoroughly explore the problem/opportunity
• Carefully select the theme
• Clearly state the theme
• Have weakness orientation
• State as a problem/gaps, not a solution
• State in terms of results
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Selecting the theme
• Weakness is difference between current situation and the target.
• Weakness orientation focuses on eliminating weakness as basis of improvement (Closing the Gap).
Current
Target
} WeaknessCustomerNeed
ActualPerformance
} Weakness
Focus on facts, processes, and root causes
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7 Step improvement process
1. Select Theme
2. Collect Data
3. Analyze Causes
4. Plan Solution and Implement
5. Evaluate
6. Standardize
7. Reflect on Process
• Define your data collection process• Appropriate to process• Multi-variable data
• Analyze the data• Stratification• Graphics• Focus on deviation
• Draw a logical conclusion• Based on facts• Focus on vital few
“Primary tool used is Pareto Diagram
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Frequently used data collection tools
CHECKSHEET
PARETO DIAGRAM
CONTROL CHART
GRAPH (RUN CHART)
HISTOGRAM
Used to systematically collect data or tabulate data. (e.g. frequency of occurrence of defect types)
Excellent method to identify vital few. (2 levels minimum) (e.g. Percent of failures due to various defect types arranged in descending order of occurrence)
Method to identify non-standard process variation (e.g. Solder paste height versus time)
Method to identify trends in data (e.g. In circuit test yield versus time)
Method to identify distribution of the data (e.g. Number or solder paste observations falling into various height ranges)
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7 Step improvement process
1. Select Theme
2. Collect Data
3. Analyze Causes
4. Plan Solution and Implement
5. Evaluate
6. Standardize
7. Reflect on Process
• Create cause-and-effect diagram from Pareto
• Investigate cause thoroughly
• Draw logical conclusions (i.e. supported by data)
Ask Why?5 times
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100%
Pareto Diagram
Man Machine
MaterialMethods
A B C D E F
A
1st why
2nd why
3rd why
4th why
5th why
• ASK 5 WHYS to get to the proper level of analysis and causes.
• Segment by 4 Ms• Man• Machine• Methods• Material
Cause effectDiagram
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Verifying Root Causes
Collect data on root causes
Use run charts, Pareto, Graphs, scattergrams, etc. to determine strength of correlation between root cause and problem
If verification fails to validate choices, return to diagram and choose new root causes to verify.
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7 Step improvement process
1. Select Theme
2. Collect Data
3. Analyze Causes
4. Plan Solution and Implement
5. Evaluate
6. Standardize
7. Reflect on Process
• Focus on the primary root causes
• Focus on solution which you can implement
• Dont try to fix everything at once
• Involve those who will be affected
• Run a controlled experiment (Pilot)
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Solution 1
Solution 2
Solution 3
Solution 4
-------
Fe
as
ibil
ity
Eff
ec
tiv
en
es
s
To
tal
Sc
ore
A tool to help determine whichsolution is best.
= HIGH = MEDIUM = LOW
Solectron Criteria
Scoring values
Possible score 3 or 2 or 1values 6 3
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You
You andOthers
Others
A tool to help determine ease or difficulty in solving specificproblems.
Equipment Methods Human Behavior
Easy Easy Difficult
Moderately Moderately Very Difficult Difficult Difficult
Very Difficult Difficult Difficult
Data Collection/Potential solutionimplementation
Area of Problem
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Solution Implementation
What When Where Who How
How will they get it done
Who is responsible for doing it
Where will it be done
When will it be done
What will be done
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7 Step improvement process
1. Select Theme
2. Collect Data
3. Analyze Causes
4. Plan Solution and Implement
5. Evaluate
6. Standardize
7. Reflect on Process
• Confirm improvement (Before and after comparison)
• Evaluate all subsequent effects
• Measure improvement gains over time
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100%
Pareto Diagram
A B C D E F
100%
Pareto Diagram
A B C D E F
Original Pareto “BEFORE
New Pareto “AFTER
}
}
Improvement
Effect onRoot Cause“Fewer defects
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7 Step improvement process
1. Select Theme
2. Collect Data
3. Analyze Causes
4. Plan Solution and Implement
5. Evaluate
6. Standardize
7. Reflect on Process
• Move from PDCA to SDCA cycle
• Revise the standard
• Create a process to detect future problems
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Plan Do
CheckAct
Std Do
CheckAct
PDCA SDCA
NewStd
Control
Improvement
Standardization
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7 Step improvement process
1. Select Theme
2. Collect Data
3. Analyze Causes
4. Plan Solution and Implement
5. Evaluate
6. Standardize
7. Reflect on Process
• Analyze strengths and weaknesses
• Determine the next problem
• Document the Quality improvement story
• Identify the critical difficulties during the process - using tools, etc.
• Identify the critical strengths
• Identify the key things the team would do differently
• Identify what key things the team needs to learn to improve the 7 step process.