3. Six Sigma Mining for Key Process Input Variables x’s Define Measure Analyze Improve Control Found Critical X’s Controlling Critical X’s All X’s 1st “Hit List” Screened List Found in Process Map Reduced in Cause & Effect Analysis Filtered in Failure Modes & Effects Analysis Validated with DOE, Hypothesis Tests, Confidence Intervals
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7. These are some questions we will need to answer! Remember, we are trying to learn How will we identify the x’s?
13. Process Maps and Flow Charts Process maps Drive reduction in variation Value Stream Flow charts Reduce Waste Our primary focus will be on Process Mapping FEED
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17. Examples - Step 1 Order Entry EDI FAX Email . . Price & availability Confirmation of order Promise date Order number . . Inputs Outputs Non- Manufacturing The 50,000 ft. view Molding Stamping C Prep C Solvent C Nozzle S . Coverage Thickness Hardness Color Leak Test . Inputs Outputs Manufacturing
20. Non-Manufacturing Example - Step 2 STEP 1 Answer Phone / Greet Customer STEP 2 Determine Part Number / price / need date STEP 3 Get PO # STEP 4 Identify ship to address, method of shipment STEP 8 Verify plant receipt of order STEP 7 Verify order info - fax to customer / transmit to plant STEP 6 Input order on computer STEP 5 Complete order worksheet
35. The Order Pickers Company “Flow Chart” RECEIVE Products Put Away Order Rec’v Pick Consolidate PACK/SHIP KEY: Process Step Inspection/Test Rework Inventory
Can still mold critters and coins. Use critters for the failure modes of wire protruding and too hard or soft. Or, make up your own for the critter or coin.
See PowerPoint of CR Bug Process Map for example class should get close results to
Conduct the quiz orally with the participants: 1 T 2 T 3 T 4 F 5 F 6 T 7 F ALTHOUGH THERE IS NOT MUCH NEED AFTER MEASURE PHASE
