6Sigma-DMAIC Problem Solving Tools

6 SIGMA QUALITY ACTION DECK FOR ROMEO ENGINE PLANTWhen solving an issue, complete each phase of D M A I CM=Measure. Develop and implement a data collection plan. Review gage R & R's, transducer verifications ect.D=Define. Review Meters. Define your problem statement. Verify priority with Manager/SFE. Review DCP, QPS & FMEA. Refer to the SGA Problem Solving Tool Book for varoius problemsolving tools to use during this phase. Re-define your problem statementA=Analyze. Analyze data that has been collected and place into appropriate chart forms. Potential Root Cause will be identified in this phase.I=Improve. Implement process improvement and validate that the team has reached its goal.C=Control. Monitor & adjust on going proformance.**After the Improve phase is complete, verify that the DCP, QPS, FMEA & visual aids have been updated per the PCR.Red=less than 50% of phase is complete.Yellow=more than 50% of the phase is complete.Green=Phase is complete.Uncontrolled Document - For Ref. OnlyGREEN BELT PROBLEM PRIORITY RESOLUTIONDepartment:__________ Operation:________ Station:________ Start Date:__________Team Members Roles/Responsibilities Team Members Roles / Responsibilities______________________ __________________________ ____________________ ______________________________________________ ___________________________ ____________________ ______________________________________________ ___________________________ ____________________ ______________________________________________ ___________________________ ____________________ ________________________D efine Phase: Refine the understanding of the problem to be addressed and select critical to quality characteristics.What can be improved (Problem) ? _____________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ What is Critical to Quality (CTQ) ?______________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ M easure Phase: Establish techniques for collecting data about the current performance of processes identified in the Define Phase.What Data needs to be collected ?__ ____________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ Validate the Measurement System (R&R)_________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ A nalyze Phase: Target improvement opportunities by taking a closer look at the data and identify source(s) of variation:_____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ Identify Root Cause(s):_______________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ Ask the 5 Whys:______________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ I mprove Phase: Develop implement and validate improvement alternatives that will achieve desired performance levels as defined by CTQs Resolution / Action Plan: Task Responsibility Target Date1._________________________________________________________________________________________________________________2._________________________________________________________________________________________________________________3._________________________________________________________________________________________________________________4__________________________________________________________________________________________________________________ 5__________________________________________________________________________________________________________________ 6__________________________________________________________________________________________________________________ 7__________________________________________________________________________________________________________________ 8__________________________________________________________________________________________________________________ 9__________________________________________________________________________________________________________________ 10_________________________________________________________________________________________________________________ C ontrol Phase: Process improvements and monitor ongoing performance in order to sustain the gains achieved in the Improvement Phase.What will be Monitored ? ___________________________________________________________________________________________ How will it be Monitored ?____________________________________________________________________________________________ ___________________________________________________________________________________________________________________ Who will Monitor ? ________________________________________________________________________________________________For Reference Only -Uncontrolled DocumentA3 -Problem Solving WorksheetProblem Statement:Measurement System Analysis / Gage R&R::Brainstorming / Fishbone:Root Cause / Pareto / Control Charts:DCP/FMEA Updates, PM Task, Error Proofing::DOE -New Process Map -Pilot:Process Mapping -Line Walks::Uncontrolled DocumentDate:___________________Team Members:_____________________________________________________________________________________________5 WHYs (Repeated Whys)1. Ask Why?2.Why?Why does it take backup operators longer to connect callers?3.Why?Why don't the backup operators know the job as well?4.Why?Why don't they have special training or job aids?5.Why?Why hasn't the organization recognized this need?*Where should you stop? What is the level at which you should take action?It depends on the scope of authority of the person or team investigating the issue.An immediate fix for the example given would be to provide at least SOME training for the* Remember to record all of your ideas. Some of these ideas can be used with other tools or possibly help with another project.BENEFITSWhen is 5 Whys Most Useful?When problems involve human factors or interactions.Customers complain about waiting too long to get connected tostaff when they call during lunch hours. Problem Statement:Backup operators take longer to connect callers.Why does this problem happen?Backup operators don't know the job as well as the regular operators/ receptionists do.There is no special training or job aids to make up for the gap in experience, and they receive all their training on the job.*Easiest tool to complete without getting into statistics.focus on the third why.In the past, the organization has not recognized these needs.*This is good tool to use after the Fishbone has been completed. Use inputs from the fishbone to drill down to the possible root cause(s).*Helps to determine relationships between different causes.*The forth and fifth whys are broader causes and are outside the scope of the problem-solving The organization has no system to identify training needs.*The first 3 Whys are progressively deeper, more specific,actionable causes. The team should current backup operators.team and should be provived to management as data about systems issues that are deep causes of problems.5 WHYs (Repeated Whys)Problem Statement:1. Why Does This Happen?2.Why?3.Why?4.Why?5.Why?* Remember to record all of your ideas. Some of these ideas can be used with other tools or possibly help with another project.Problem Solving WorksheetIS / IS NOT1. Problem Statement2. ProblemDiscription IS IS NOT Get information TAHWEREHWNEHWGIBWOHGage R and RDate: ___________________Part #: _______________________________________Characteristic to be checked: _____________________Trial 1Trial 2 Operator 1:Part Number Value Part Number Value 1631083287167495495102Operator 2:Part number Value Part Number Value 5871065341039122168749Operator 3:Part number Value Part Number Value 101016893724487291536507/30/2004Page 1 of 1Data EntryAttribute Gage R & R EffectivenessSCORING REPORTDATE:Attribute Legend5(used in computations)NAME:1pass PRODUCT:All operators2fail BUSINESS:agree within and All Operatorsbetween each agree withOther standardOperator #1Operator #2Operator #3Known Population Y/N Y/N Sample #Attribute Try #1Try #2Try #1Try #2Try #1Try #2Agree Agree 123456789101112131415161718192021222324252627282930% APPRAISER SCORE(1) ->#DIV/0!#DIV/0!0%% SCORE VS. ATTRIBUTE(2) ->Known Known KnownSCREEN % EFFECTIVE SCORE(3) ->0.00%SCREEN % EFFECTIVE SCORE vs. ATTRIBUTE (4) ->0.00% Note:(1)Operator agrees with him/herself on both trials(2)Operator agrees on both trials with the known standard(3)All operators agreed within and between themselves(4)All operators agreed within and between themselves AND agreed with the known standard(5)Enter Pass/Fail, Good/Bad, Accept/Reject or other labels which indicate status of inspectionPage 1。