storyboard_ssgb_v 10.1
DESCRIPTION
greenbelt, six sigma, story board, green belt project.TRANSCRIPT
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Project Leader:
*
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Standard FONT to be used across the presentation.Standard size of Graphs/Outputs from Minitab
- * -Standard Instructions
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- * -Define Phase Deliverables
DeliverableTarget Completion DateActual Completion DateProject Charter VOC - VOBFinancial Validation SheetKANO / Project Priority Calculations / Balanced Scorecard /CSAT Analysis (Justify need of Project)Macro MapSIPOCStakeholder AnalysisMetrics Tracker (Graphical Representation)
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- * -MEASUREANALYZEIMPROVECONTROLDEFINEProject LeaderProject MentorTeam MembersProject ChampionProject SponsorProcess OwnerProject Charter
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* xxxxxxxxxxxxxxxxxx xxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxx xxxxxxxxxx xxxxxxxx-Customer , Designation
xxxxxxxxxxxxxxxxxx xxxxxxxxxxxxx xxxxxxxxxx xxxxxxxxxxxxxx xxxx xxxxxxxxxxx xxxxxxxxxx xxxxxxxxx xxxxxxxx-Process Owner, Designation- * -Benefits from the projects ( choose from whatever is applicable) : - Customer SLA , CSAT Score , Growth ,Profitability, Retention ,Any other ( pls specify)
Financial Benefit Calculation ( Show calculations ) : xxxxxxxxxxxxxxxxxx xxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxx xxxxxxxxxx xxxxxxxxxxx xxxxxxxxxx xxxxxxxxx xxxxxxxx( To be discussed with Finance rep)
VOCVOBVOC VOB & Benefits
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Need of Project- * -
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- * -Macro Map
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SupplierSIInputOutputCustomerProcess CPO- * -SIPOC
Activity
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X=Where this Stakeholder IS TODAY on the ProjectO=Where this Stakeholder NEEDS TO BE on the Project* When Populating the Stakeholder, consider the ARMI:A= Approver of team decisionsR= Resource or subject matter expert (ad hoc)M= Member of teamI= Interested Party who will need to be kept informedStakeholder Analysis
Stakeholder ARMI*Strongly OpposedOpposedNeutralSupportiveStrongly SupportiveStakeholder Name / RoleXOStakeholder Name / RoleStakeholder Name / RoleStakeholder Name / RoleStakeholder Name / RoleStakeholder Name / Role
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*- * -Graphical Representation is requiredMetrics Tracker
Primary MetricBaselineGoalMonMonMonMonMonMonMonMonMonMonMonMon
Consequential Metric
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- * -Measure Phase Deliverables
DeliverableTarget Completion DateActual Completion DateAs Is Process MapValue Analysis & List of Quick WinsImproved Process MapMeasurement System AnalysisData Collection Plan for YNormality, Stability TestingCapability AnalysisIdentification of Input, process and output indicatorsCause and Effect DiagramConversion of Causes to XsCause - Effect MatrixData collection Plan
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*- * -
AS IS Process Map
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- * -Value Analysis
ActivityClassification of ActivityQuick Win OpportunityProposed SolutionsTools UsedResponsibilityCVAOVANVAStep # 1 N/AStep # 2 Solution # 1 Brainstorming
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- * -
Improved Process Map
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A sample worksheet where 3 operators look at a piece and decide whether it is a Defect or Not based on a classification criteria in 2 trials each- * -Measurement System Analysis
Calculations
Attribute Gage R & R
Attribute Legend
1Date:
2Name:0
3Process name:
4Project:
AccuracyRepeatability NeumratorRepeatability DenominatorReproducibility NeumratorReproducibility DenominatorMeasurement Efficiceny NumMeasurement Efficiency Dem
Known PopulationOperator #01Operator #02Operator #03Known PopulationOperator #01Operator #02Operator #03Known PopulationOperator #01Operator #02Operator #03Known PopulationOperator #01Operator #02Operator #03Known PopulationOperator #01Known PopulationOperator #01Known PopulationOperator #01Known PopulationOperator #01
Sample #MasterTrial #01Trial #02Trial #01Trial #02Trial #01Trial #02Sample #MasterTrial #01Trial #02Trial #01Trial #02Trial #01Trial #02Sample #MasterTrial #01Trial #01Trial #01Sample #MasterTrial #01Trial #01Trial #01Sample #MasterTrial #01Sample #MasterTrial #01Sample #MasterTrial #01Sample #MasterTrial #01
1------1------1---1---1-1-1-1-
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Datasheet
Attribute Gage R & R
Attribute Legend
1Date:
2Name:
3Process name:
4Project:
Known PopulationOperator #01Operator #02Operator #03
Sample #MasterTrial #01Trial #02Trial #01Trial #02Trial #01Trial #02Guage R&R Results
1
2Overall Accuracy
3
4Repeatability
5
6Reproducibility
7
8Measurement Efficiency0%
9
10ConclusionNot OK
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Clear Data
Reset All
Calculate
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*- * -Process InformationData Collection Plan for Y
MeasureData typeWhatHowFrequencySourcePeriodSizeY1Y2
DomainFTE SizeOpn WindowTypeProductClientBilling Type
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*- * -
Normality & Stability Testing
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*- * -
Capability Analysis
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*Sigma Calculator for non-normally distributed Y or Discrete (Attribute) data Type- * -CA Discrete Data
Sheet1
Sheet2
Sheet3
Process Sigma Discrete
Process Sigma Calculator - Discrete Data
Number of Units ProcessedN26
Total Number of DefectsD20
Number of Defect Opportunities per UnitO1
Defects per million opportunitiesdpmo769230.8
Defects as percentage76.92%
Process Sigma LevelSigma0.76
Notes:
1. Total number of defects should include defects made and later fixed.
2. Sigma level incorporates 1.5 sigma shift.
3. Sample size should be large enough to observe 5 defects.
0.23
SigmaXL Copyright 2004-0.26923076920.1081397929
1.08140E-017.6923E-01
1.4914189116
0.761.2364815594
-0.7363159174
-0.1085810884
-3.50858E+00
-0.73631591740.7636840826
1.23648155942.7364815594
-0.18165861851.3183413815
2.50908092873E+03
3.34305755836E+04
6.72657709270E+04
4.59219539315E+04
1.37316937655E+04
1.97159095031E+03
1.33141667892E+02
3.38713287280E+00
5.22649527885E+03
2.87290857357E+04
3.93078958001E+04
2.12137943016E+04
5.39419602142E+03
6.87187007492E+02
4.23133307016E+01
7.74545014278E-04
2.27238449893E-02
2.41780725177E-01
1.27045825245E+00
3.64784832476E+00
5.76949722146E+00
4.63033784616E+00
1.42343711075E+00
2.05319162664E+00
1.67638483018E+00
6.89767334985E-01
1.48103976427E-01
1.51986665636E-02
5.47593808500E-04
1.05075007164E-09
6.65790464350E+00
5.46378491116E+00
1.78482653992E+00
2.96560571829E-01
2.65321895266E-02
1.24266094739E-03
2.71155556874E-05
2.01033439929E-07
5.99832206556E-01
1.36929880923E-01
1.48753612909E-02
7.86869131146E-04
1.84631831751E-05
1.42151175832E-07
2.04426310339E-15
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*Help : To be used only if Y is normally distributed.- * -CA Continuous Data
Sheet1
Sheet2
Sheet3
Process Sigma Discrete
Process Sigma Calculator - Discrete Data
Number of Units ProcessedN1000
Total Number of DefectsD10
Number of Defect Opportunities per UnitO1
Defects per million opportunitiesdpmo10000.0
Defects as percentage1.00%
Process Sigma LevelSigma3.83
Notes:
1. Total number of defects should include defects made and later fixed.
2. Sigma level incorporates 1.5 sigma shift.
3. Sample size should be large enough to observe 5 defects.
0.99
SigmaXL Copyright 20040.49-0.059475
1.00000E-021.0000E-02
2.1459659586
3.832.326347765
2.326347765
0.5459659586
-2.85403E+00
2.32605335183.8260533518
2.3263477653.826347765
-0.86322404970.6367759503
2.50908092873E+03
3.34305755836E+04
6.72657709270E+04
4.59219539315E+04
1.37316937655E+04
1.97159095031E+03
1.33141667892E+02
3.38713287280E+00
5.22649527885E+03
2.87290857357E+04
3.93078958001E+04
2.12137943016E+04
5.39419602142E+03
6.87187007492E+02
4.23133307016E+01
7.74545014278E-04
2.27238449893E-02
2.41780725177E-01
1.27045825245E+00
3.64784832476E+00
5.76949722146E+00
4.63033784616E+00
1.42343711075E+00
2.05319162664E+00
1.67638483018E+00
6.89767334985E-01
1.48103976427E-01
1.51986665636E-02
5.47593808500E-04
1.05075007164E-09
6.65790464350E+00
5.46378491116E+00
1.78482653992E+00
2.96560571829E-01
2.65321895266E-02
1.24266094739E-03
2.71155556874E-05
2.01033439929E-07
5.99832206556E-01
1.36929880923E-01
1.48753612909E-02
7.86869131146E-04
1.84631831751E-05
1.42151175832E-07
2.04426310339E-15
Process Sigma Continuous
Process Sigma Calculator - Continuous Data
Enter Mean:X-bar
Enter Standard Deviation:S
Enter USL:
Enter LSL:
Expected ppm > USL
Expected % > USL0
Expected ppm < LSL0
Expected % < LSL
Yield %100.00%
Sigma Level0.001
0.5-0.069375
0.00000E+000.0000E+00
0.000
0
SigmaXL Copyright 20040
0
0.00000E+00
3.20561446684.7056144668
00
00
2.50908092873E+03
3.34305755836E+04
6.72657709270E+04
4.59219539315E+04
1.37316937655E+04
1.97159095031E+03
1.33141667892E+02
3.38713287280E+00
5.22649527885E+03
2.87290857357E+04
3.93078958001E+04
2.12137943016E+04
5.39419602142E+03
6.87187007492E+02
4.23133307016E+01
7.74545014278E-04
2.27238449893E-02
2.41780725177E-01
1.27045825245E+00
3.64784832476E+00
5.76949722146E+00
4.63033784616E+00
1.42343711075E+00
2.05319162664E+00
1.67638483018E+00
6.89767334985E-01
1.48103976427E-01
1.51986665636E-02
5.47593808500E-04
1.05075007164E-09
6.65790464350E+00
5.46378491116E+00
1.78482653992E+00
2.96560571829E-01
2.65321895266E-02
1.24266094739E-03
2.71155556874E-05
2.01033439929E-07
5.99832206556E-01
1.36929880923E-01
1.48753612909E-02
7.86869131146E-04
1.84631831751E-05
1.42151175832E-07
2.04426310339E-15
-
*Please do not select Primary Metric as Output Indicator.- * -IPO Metrics
-
- * -What are the Potential Causes of the Defect? (Enter it for your project in the form of a question)MaterialsPeopleMethods / ProceduresMachines / EquipmentMeasurementEnvironmentSample text for you to replaceSample text for you to replaceSample text for you to replaceSample text for you to replaceSample text for you to replaceSample text for you to replaceSample text for you to replaceSample text for you to replaceEffect (Y)Potential Causes (Xs)Cause & Effect Diagram
-
- * -Conversion of Cause to Xs
Sr. No.Root Cause Corresponding XD/ CUnit of Measure
-
- * -Cause & Effect Matrix
Cause-Effect MatrixOutput #1Output #2Output #3Output #4
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*- * -Data Collection Plan for X
MeasureData typeWhatHowFrequencySourcePeriodSize
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- * -Analyze Phase Deliverables
DeliverableTarget Completion DateActual Completion DateFMEAList of FMEA Action PlansExploratory Graphical TestingStatistical Test Plan and ResultsValidated X's Summary
-
- * -FMEA
FMEA
Failure Modes & Effects Analysis
Process/Product:Loan Application ProcessFMEA Date: (original)
FMEA Team:(Revised)
Black Belt:Revision Mo:
ProcessActionsResults
Item Process StepsPotential Failure ModePotential Effects of FailureSeverityPotential Cause(s) of FailureOccurrenceCurrent ControlsDetectionRisk Priority NumberRecommended ActionResponsibility and Target Completion DateAction TakenSeverityOccurrenceDetectionRisk Priority Number
Process Steps identified from Top Down ChartIn what ways might the process step may failWhat is the effect of each failure mode on the outputs or Primary metric?How Severe is the effect on the output or the primary metric?What is the root cause of failure mode?Describe in terms of something that can be corrected or controlled.How often does the cause or failure mode occur?What are the existing controls and that either prevent failure mode from occurring or detect the failure should it occur?How well can you detect cause or FM?SEV x OCC x DETWhat are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Should have actions only on high RPN's or easy fixes.Who is responsible for the recommended action?List the completed actions that are included in the recalculated RPN.What is the new severity?What is the new occurrence?Where are the new detection capabilities?Recompute RPN after actions are complete.
Customer calls customer serviceNo custoemr service rep to pickup callsUnsatisfied customer taking business to competitors9Customer service reps too busy7Process and resource audit conducted every six months53150
9Not enought phone lines5None104500
0
0
0
0
0
0
0
0
0
0
0
0
0
&L&"Arial,Bold"&10TCS Confidential
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- * -
Action Plan based on FMEA
-
- * -
Validated Xs
X Data TypeY Data TypeTest UsedInference
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- * -Identification of Critical Xs
-
- * -Improve Phase Deliverables
DeliverableTarget Completion DateActual Completion DateSolution Generation for Validated X'sPilot Implementation PlanPilot ResultsHypothesis test / Sigma Level CalculationControl ChartsFinancial Benefit EndorsementHorizontal Deployment
-
- * -Statistical AnalysisGEMBA - Observations on FloorSolutions Generated
Validated XsPossible SolutionsAccepted (Y/N)Tool Used
ObservationsPossible SolutionsAccepted (Y/N)Tool Used
-
- * -Pilot Solution Implementation
-
Sigma Calculator for non-normally distributed Y or Discrete (Attribute) data Type- * -Process Sigma After Discrete
Sheet1
Sheet2
Sheet3
Process Sigma Discrete
Process Sigma Calculator - Discrete Data
Number of Units ProcessedN
Total Number of DefectsD
Number of Defect Opportunities per UnitO
Defects per million opportunitiesdpmo0.0
Defects as percentage0.00%
Process Sigma LevelSigma0.00
Notes:
1. Total number of defects should include defects made and later fixed.
2. Sigma level incorporates 1.5 sigma shift.
3. Sample size should be large enough to observe 5 defects.
0.00
SigmaXL Copyright 200400
0.00000E+000.0000E+00
0
0.000
0
0
0.00000E+00
00
00
00
2.50908092873E+03
3.34305755836E+04
6.72657709270E+04
4.59219539315E+04
1.37316937655E+04
1.97159095031E+03
1.33141667892E+02
3.38713287280E+00
5.22649527885E+03
2.87290857357E+04
3.93078958001E+04
2.12137943016E+04
5.39419602142E+03
6.87187007492E+02
4.23133307016E+01
7.74545014278E-04
2.27238449893E-02
2.41780725177E-01
1.27045825245E+00
3.64784832476E+00
5.76949722146E+00
4.63033784616E+00
1.42343711075E+00
2.05319162664E+00
1.67638483018E+00
6.89767334985E-01
1.48103976427E-01
1.51986665636E-02
5.47593808500E-04
1.05075007164E-09
6.65790464350E+00
5.46378491116E+00
1.78482653992E+00
2.96560571829E-01
2.65321895266E-02
1.24266094739E-03
2.71155556874E-05
2.01033439929E-07
5.99832206556E-01
1.36929880923E-01
1.48753612909E-02
7.86869131146E-04
1.84631831751E-05
1.42151175832E-07
2.04426310339E-15
-
Help : To be used only if Y is normally distributed.- * -Process Sigma After Continuous
Sheet1
Sheet2
Sheet3
Process Sigma Discrete
Process Sigma Calculator - Discrete Data
Number of Units ProcessedN1000
Total Number of DefectsD10
Number of Defect Opportunities per UnitO1
Defects per million opportunitiesdpmo10000.0
Defects as percentage1.00%
Process Sigma LevelSigma3.83
Notes:
1. Total number of defects should include defects made and later fixed.
2. Sigma level incorporates 1.5 sigma shift.
3. Sample size should be large enough to observe 5 defects.
0.99
SigmaXL Copyright 20040.49-0.059475
1.00000E-021.0000E-02
2.1459659586
3.832.326347765
2.326347765
0.5459659586
-2.85403E+00
2.32605335183.8260533518
2.3263477653.826347765
-0.86322404970.6367759503
2.50908092873E+03
3.34305755836E+04
6.72657709270E+04
4.59219539315E+04
1.37316937655E+04
1.97159095031E+03
1.33141667892E+02
3.38713287280E+00
5.22649527885E+03
2.87290857357E+04
3.93078958001E+04
2.12137943016E+04
5.39419602142E+03
6.87187007492E+02
4.23133307016E+01
7.74545014278E-04
2.27238449893E-02
2.41780725177E-01
1.27045825245E+00
3.64784832476E+00
5.76949722146E+00
4.63033784616E+00
1.42343711075E+00
2.05319162664E+00
1.67638483018E+00
6.89767334985E-01
1.48103976427E-01
1.51986665636E-02
5.47593808500E-04
1.05075007164E-09
6.65790464350E+00
5.46378491116E+00
1.78482653992E+00
2.96560571829E-01
2.65321895266E-02
1.24266094739E-03
2.71155556874E-05
2.01033439929E-07
5.99832206556E-01
1.36929880923E-01
1.48753612909E-02
7.86869131146E-04
1.84631831751E-05
1.42151175832E-07
2.04426310339E-15
Process Sigma Continuous
Process Sigma Calculator - Continuous Data
Enter Mean:X-bar
Enter Standard Deviation:S
Enter USL:
Enter LSL:
Expected ppm > USL
Expected % > USL0
Expected ppm < LSL0
Expected % < LSL
Yield %100.00%
Sigma Level0.001
0.5-0.069375
0.00000E+000.0000E+00
0.000
0
SigmaXL Copyright 20040
0
0.00000E+00
3.20561446684.7056144668
00
00
2.50908092873E+03
3.34305755836E+04
6.72657709270E+04
4.59219539315E+04
1.37316937655E+04
1.97159095031E+03
1.33141667892E+02
3.38713287280E+00
5.22649527885E+03
2.87290857357E+04
3.93078958001E+04
2.12137943016E+04
5.39419602142E+03
6.87187007492E+02
4.23133307016E+01
7.74545014278E-04
2.27238449893E-02
2.41780725177E-01
1.27045825245E+00
3.64784832476E+00
5.76949722146E+00
4.63033784616E+00
1.42343711075E+00
2.05319162664E+00
1.67638483018E+00
6.89767334985E-01
1.48103976427E-01
1.51986665636E-02
5.47593808500E-04
1.05075007164E-09
6.65790464350E+00
5.46378491116E+00
1.78482653992E+00
2.96560571829E-01
2.65321895266E-02
1.24266094739E-03
2.71155556874E-05
2.01033439929E-07
5.99832206556E-01
1.36929880923E-01
1.48753612909E-02
7.86869131146E-04
1.84631831751E-05
1.42151175832E-07
2.04426310339E-15
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- * -Control Phase Deliverables
DeliverableTarget Completion DateActual Completion DateControl PlanControl ChartsFinancial Benefit Calculation and endorsementProject transition action planHorizontal Deployments & Benefits realizedProject summary ( Four Blocker )
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- * -Control Plan
Control Plan
Control PlanSPC / SPM
Process StepWhat'sControlled?Measurement MethodControl MethodFrequencyResponsibilityDecision Rule/ Corrective ActionInspection
Process step from TDCMention the parameter (Input-X / Output - Y) being controlledHow will you measure / know the status/value of the parameter "What's Controlled"?How will you ensure that the parameter remains within specifications or meets requirements?What is the frequency / interval for sample collection/ measurement?Who is responsible for taking the actionWhat action should be taken in case the parameter fails to meet requirements/ specification? What will be the action if repeated failures happen?SOP
SOP
Warning Signal
&L&"Arial,Bold"&10TCS Confidential
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- * -Control Charts
-
- * -Benefits from ProjectComparison with the actual & estimated benefitse.g Must clearly indicate breakthrough improvement as a result of the project in one or more of the following ways:Reduction in defects (90% or more) Increase in process sigma level (minimum of 2-sigma increase if initial sigma level was less than or equal to 3; minimum of 1-sigma increase if initial sigma level was greater than 3) Financial benefit (minimum $250,000 in U.S. dollars AND 5x or more return on investment, calculated to include the cost of the project and resulting expenses) Customer Endorsement or Business EndorsementFinancial Benefit Calculation & Endorsement
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Detailed worksheet - * -Project Transition Action Plan
PTAP
Project Title:
Transition Owner:
Plan Date:
Actions Required for CompletionActionOwnerInitialsScheduledCompletionActualCompletion
1
2
3
4
5
6
7
8
9
10
11
Signatures:
Transition Owner
Process Owner
Master Black Belt
Black Belt
Project Transition Action Plan
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- * -Horizontal Deployments
-
.
- * -Project Summary
-
Thank You
**Help Slide Not Critical*Non Critical*Critical*Critical*Critical*Not Critical*Critical**CriticalNot CriticalNot Critical*Critical Use Swim lane , Top down chart as deemed appropriate.**Critical
*Critical
Draw Example of Possible Quick Wins on flip chart
Possible Quick Wins:
Eliminate sales rep from process,Determine whether loan or lease at earliest stepDont hang up until application completeSales reps answer phonesCritical ( Optional )
It is necessary to classify each occurrence with its TRUE value.For example, if parts are to be declared as either Non-defective or Defective, the truth column provides N or D, depending on if that part is truly defective or not.
The data sheet still uses three operators and three trials to measure both reproducibility and repeatability. The response of each operator on each trial (N or D) is compared to the truth column.
There is no set number of samples that must be taken, however when the analysis is complete it will be more apparent the need for larger sample sizes. *Critical
Critical
*Critical (Optional Slide 16/17 or 18)
*Critical (Optional Slide 16/17 or 18)
*Critical (Optional Slide 16/17 or 18)
*Non Critical
*Critical*Critical*Not Critical*Critical*Not Critical**CriticalCritical*Critical*Critical*Not Critical
*Critical*Critical*Critical (Optional Slide 33/34)*Critical (Optional Slide 33/34)
*Non Critical
**CriticalCritical*Critical*Non Critical*Critical ( Optional in cases where there are no HDs)**Critical**Non Critical