Analyse Phase

Tools used in the Analyse Phase

       ·         AS IS Process Map Analysis

·       Brainstorming
Initial Brainstorm ( On Seven Wastes)

Brainstorm Action Plan
Pareto Chart Analysis
Cause & Effect Analysis
Cause & Effect Action Plan

·         5 Why’s Analysis

AS IS Process Map

In our Process Map Analysis our process has not changed, but more important at this point is the supporting process data which is key to enable accurate analysis of the process/performance. Shift reports now showing key information on Process, efficiency & waste data are giving the full picture.

Brainstorming

Brainstorming is the basis behind the tools used which has identified the areas where this project needs to work on to succeed. Our first session was an open brainstorm with a focus on the 7 wastes, the post it ideas were put into the following 4 groupings, most likely to impact, possible impact, no impact and finally not possible. Out of these we got our action plan where actions were given owners and timescales for completion.

 

 

Image Ref http://wongwowai.wordpress.com/2008/09/15/7-wastes-introduction/ also on this site you will find a simple but straightforward description of each of the seven forms of waste.

 

Then it was a cause & effect diagram which along with the pareto analysis already put together in our measure phase created our second series of actions. The pictures below shows the C&E from the initial session and also the edited version where all information was grouped, screened and prioritized into actual causes of waste which could be addresses by the team.

                         

These causes using the screening of “how likely” and “how easy” allowed the team to focus on causes that would impact this project in achieving its target and it is from here we developed the Cause & Effect action plan.

5 Why Analysis

This was the final tool used in the analyse step. It was used with what the team termed a grey area “this is a problem we all know and about but nobody knows how we can fix”

In using the 5 whys this forced the question so far that we discovered we had a resource (ingredient supplier) right under our noses which would be at no cost the plant and was available to deliver exactly what we needed.



Next Stage we have moved on to the Measure Phase

 

Tools used in the Measure Phase

Critical To Customer Tree (CTC)
Metric Table
Before Performance (Control Charts)
Quality Score Dashboard
Before Mechanical Performance (Control Chart)
Top Six Pareto Analysis
Estimated CBA

 Critical To Customer Tree (CTC)

 

Firstly the Team objective was to create a Critical to Customer Tree, in completing this we got a good understanding of the customer needs and we could identify what measures would show us clearly those needs.
We also identified and agreed what measures we could use from start to finish of the project to show if we were making progress on achieving the customer needs
From some of the project team members previous experience the following three needs were put forward to get the ball rolling. Perfect, Free & Now

Metric Table

Next the Metric Table so we could keep a record of all current and potential measures of the process. This helped insure we had had a good quality countermeasure so product quality would not suffer if we focused only on the waste metrics.

Before Performance (Control Charts)

On to the Control Charts, this I personally put a huge focus on and you will see this as these are the main measures of the before performance. I wanted to improve my knowledge and also the rest of the teams understanding of how these show where a process is at and how wide apart the UCL and LCL can be when a process is struggling.

 

Quality Score Dashboard

Quality Base score card showed us a good visual countermeasure to help maintain a balanced focus of the process to maintain the standards of the Product. This measure was also key to balance the project as we have no member from the quality department.

Before Mechanical Performance (Control Chart)/ Top Six Pareto Analysis

 Our second control chart was on mechanical downtime which along with the Pareto analysis showed what we were dealing with in terms of unreliable performance. We may have went a step too far at this point is pulling out our six worst weeks performance and graphing these into Pareto analysis charts  but this will be beneficial when we move to the analyse stage.

             

 

Estimated Cost and Benefits Analysis

Finally the Cost benefit analysis was completed and this I would have to say was an excellent way for the team to finish the measure phase of the project. To see the potential savings and have these validated by a member of Group Finance was a real eye opener. It has also proven that this project is well worth doing and will impact the business in a very positive way going forward by reducing material variance.

This is a Blog for my 6 Sigma project which I am completing as part of the course I have taken through IT Sligo in Manufacturing Management

Project Overview

The aim with this project is to use the six sigma process design and improvement tools to drive waste down in the production of pizza bases. We hope to identify areas where we can implement improvements or tighter control which will in turn reduce the overall waste in the process.

The Team

Putting a team together to work on any project, be it capital project or improvement always provides some interesting outputs and this team is proving no different. We have met the challenge of having team members from different shifts where communication and inputs are sometimes not always in synchronisation (this have been a real challenge). On the other hand the unknown strengths of some members have come to light and these are what have put the energy into this project

In the define stage of the project we used the following tools,

Project Charter – This included the scope of the project and all team members

Problem Statement and why this project was selected

Related Projects and Customers Impacted

Benchmarking Activity

COPIS

Flow Diagram

Gantt Chart

The one tool that stands out in the define process is the Problem Statement and why this project was selected. This really provided the debate but in the end left us with a clear idea of what the problem was and what we needed to focus on.

On the other hand the COPIS was not so clear and until we put together the Process Flow Map I think we were a little unclear of who and what the suppliers really were to our process

Below is a picture of some of the team members working on about the third COPIS we developed.