06 process analysis methods

7/23/2019 06 Process Analysis Methods

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1

Six Sigma

Green Belt

-6 -4 -2 0 2 4 6

Process Analysis Methods


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2

Six Sigma

Green BeltLow Hanging Fruit

Inefficiency Description/Example Action

Duplication When we make reservations with most hotel chains, we provide themwith our name, address, etc. When we arrive at the actual hotel, theprobability that we will have to give that same inormation is usually veryhigh.

!liminate unnecessaryduplication

MisplacedActivity

"t a amous car manuacturer, the glove bo# was installed at point $"% onthe line. "t point $&,% down the line, the glove bo# was removed to installsome electrical wiring.

'eorder process steps

Storage (tored material, supplies, etc., takes up space and incurs cost.

!#amples range rom manuacturing in-process inventoryto the $vast%amount o pens, pencils, and stationery $stored% in oice buildings.

)inimi*e storage,

implement +ust-in-imedelivery

Transport ransportation does not add value to the material or product beingtransported consider also the $transport% o customers through yourprocesses

)inimi*e wasted transports

Motion /ten people do things a certain way because o habit, not because it sthe best way to perorm a task.

)inimi*e wasted motion

Inactivity heres an old saying, $A person watching a machine is not working./ne o our uality riends was curious to know why an automatedproduction line was shut down when the workers went on break.1

)inimi*e or eliminate.


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Six Sigma

Green BeltThe Five Ss!


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4

Six Sigma

Green Belt"as the Process Followed#

START

Is there

a standard that, if

folloed, ould haveprevented the

event!

"as

the standard#olloed!

$%

&ES$%

&ES 'ould it have

(een folloed if

)their life dependedon it*

&ES

$%

Either + 'reate the standard train,

and/or simplify the tas- or process

Either + Modify the standard train,

and/or simplify the tas- or process

"as the

individual aare of

the conse.uencesof their action!

$%

&ES

'ultural 01234 5 %rgani6ational )(ehaviors*

re.uire change7

Individual 0234 5 Individual (ehavior re.uires

ad8ustment

Inadvertent Error5 9oint out )(ad*

effects of the

action, if not

already o(vious

Techni.ue Issue

5 Discover there.uired )-nac-*

and train

STA$DARD means policies, procedures, training,

chec-lists and other items that are supposed to

prescri(e the ay specific tas-s are to (e done7

The items shon in the gray (oxesare )human factors*

issues7 Appropriate countermeasures ould (e generated

directly from this analysis ithout the need for additional

root cause analysis or-7

"hy Does the "rong/Inappropriate9rocess Exist! Are There %ther

'ases :i-e This!

"hy Does the "rong/Inappropriate9rocess Exist! Are There %ther

'ases :i-e This!

"hy "asn;t a 9rocess in

9lace! Are There %ther

'ases :i-e This!

"hy "asn;t a 9rocess in

9lace! Are There %ther

'ases :i-e This!


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3

Six Sigma

Green Belt$om%arative Process Analysis

1. dentiy how the process operated when the problem

occurred,

2. dentiy how the process operates when noproblem

occurs, and

. (eek out the dierences between the two. "dopt the best

method o perorming the process.


6/19

6

Six Sigma

Green BeltTwenty &uestions

Where is it

done5

What

happens5

When is it

done5

Why them5

Who does

it5

ow is it

done5

&an we do itsome other

way5

&an some -body else do

it5

&an we do itsome other

time5

&an we doit some-

where

else5

&an wedo some-

thing

else5


7/197

Six Sigma

Green BeltManaging 'elia(ility

To ensure the relia(ilityof a process, wemust manage the process )ailures.


8/198

Six Sigma

Green BeltFM*A Pur%oses

&hecking and improving the system9s design as it e#ists

on paper.

dentiying those critical components that reuired

e#tensive testing to determine their reliability.

:lanning the system9s maintenance program to determinepreventive and corrective maintenance actions.

mproving the reliability o e#isting systems by identiying,

ranking, and improving critical components o systems or

processes.


9/19

;

Six Sigma

Green BeltFM*A *xam%le


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Six Sigma

Green Belt+, List the Failure Mode-s. o) the /tem

:remature /peration


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Six Sigma

Green Belt3, List the Possi(le $auses o) the Mode

Man

Method

MaterialsMachine

Environment

#ailure

Mode

?eective )aterial ?eective :rocessing ?eective "ssembly


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12

Six Sigma

Green Belt4, 0etermine 0etection A(ilities

?uring /peration

?uring &onstruction=)anuacture


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1

Six Sigma

Green Belt5, Prioriti6e Failure Modes7$auses

'isk :riority Cumber ':C

FA/L8'* P'9BAB/L/T: S$9'*


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14

Six Sigma

Green Belt5, Prioriti6e Failure Modes7$auses

'isk :riority Cumber ':C

P'9BAB/L/T: 9F FA/L8'* 0*T*$T/92 S$9'*

:ossible to detect almost every ailure in-house prior to construction=assembly

i.e. at receipt inspect ion

1 - 2

)ostly detectable prior to completion o construction= maintenance. Asually

detected during assembly=it -up

- 4

Andetectable until turnover to operations. )ost ailures detected during startupor post -maintenance testing

3 - 6

Andetectable until use by operations=end-user. )ost ailures detected during

operations=periodic testing

7 - 8

Andetectable until demanded by abnormal condition= accident, not detectable

during operations=periodic testing.

; - 10


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Six Sigma

Green Belt


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Six Sigma

Green BeltPo=a>:o=e? A%%roaches and *xam%les

I7 9revent ErrorsA, *liminate the %ossi(ility o) the error

>awn mower must have saety barengaged to start engine

Bas cap tethered to car so it cannotbe let behind

B, 0elegate decisions

&ash register calculates change

/ne-touch setting or popcorn on amicrowave

$, Facilitate tas=s

:rogram @&' using a program

code Wires that connect are color coded

II7 Mitigate ErrorsA, 0etect *rrors

"uto-shut o on coeemakers

and irons

(pell checking in word

processor

B, Mitigate *rrors 'adar or collision avoidance

"utomatic correction o

spelling errors in a word

processor

? @a%anese Term )or *rror Proo)ing

Si Si


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Six Sigma

Green BeltThe Best Po=a>:o=e

Si Si


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Six Sigma

Green BeltThe Best Po=a>:o=e

Si Si


19/19

1;

Six Sigma

Green Belt*xam%le o) Po=a>:o=e ty%e control

06 process analysis methods

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