project review questions ops review project facilitation process excellence
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Project Review Questions
Ops ReviewProject Facilitation Process Excellence
Project Charter (Define)
Questions• What is the expected business impact?• What is the business impact to date?• What is the problem and where is it
focused?• Has this been worked on before and
how are you leveraging that effort?• What are the boundaries of the
process?• Who is on the team and who is
sponsoring the effort?• How effective is the team and the
facilitator (Black Belt)?• What are the important lessons learned
(both good and bad)?• What actions were taken to correct for
any issues uncovered?• What barriers to success exist?
OPS REVIEW
Project Plan (Define)
Questions• What has been completed since the last
review?• What are the necessary deliverables
from the Measure Phase and have they been completed?
• Have Performance Reports been used to communicate with the rest of the business?
• Is a Visual Workplace established and current?
• How detailed is the plan going forward?
Monthly Report
Step Key ActionWho'sResp. Date Status
Estimated Impact Dent Rate Reduction
(BSL = 3.3%)
1 Improve Plate Cleaner Water Quality Bockstanz Feb-97Complete - Monitoring
water quality every load0.10%
2 Cover Exposed Pallet Boards with Tack ClothCho Smith and 1D
Layup TeamMay-97
Complete - all shifts following procedures. Need to put audit into
control plan
0.10%
3 Treater 6 and 7 edge seal improvements B. Griebler, P. HajjarMay-97
and Sep-97
Complete -Edge seals complete, better edge sealing reducing dust
0.50%
4 Layup Cleanroom Upgrade P. Smith, Bockstanz May-97Complete - Room
complete, Class 1000 or better near layup area
0.50%
5 B-stage Sealing with Hand Held Heat Guns C. Dunlap, Bockstanz Jun-97
Complete - Sealing cross cut and previously sealed
edges in the stack. Greatly reduces epoxy
dust
0.50%
6 Improved Cleanroom Practices Bockstanz Jun-97
Ongoing - Operator training, awareness.
Gowning, housekeeping and procedures improved
0.10%
7 New Release Sheets C. Dunlap, Bockstanz Jul-97Replaced Fluorglass with Chemfab - no more PTFE
delamination0.10%
8 Plate Cleaner Improvements Bockstanz Aug-97
Complete - reversed top brush to elliminate plates
from sticking. Also allowed more pressure to
be put on plates, thus cleaner plates.
0.30%
9 New Tack Wipe MachinesE. Shrewsbury,
BockstanzDec 97 and
????
First new machine due December. Next ????.
Will improve wipe efficiency.
0.50%
10 Central Vacuum in Prebuild D. Smith, Bockstanz Nov-97Used for Cleaning and vacuuming dust during
prebuild.0.10%
11 Install Tec Nec Rollers E. Seay, Bockstanz Jun-98
Will improve plate cleanliness along with
modifying plate conveyors to reduce black inclusion
dents
0.20%
Report Date: October 31 Project Baseline = 3.3%. Goal = 2.0% then 1.5% in Q1 1998. Current dent rate = 1.93%. Savings to date = $106,000. Annualized savings = $350,000.
Dent Rate
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
Month
De
nt
Ra
te (
%)
Dent Rate Goal
ID Task Name
1 Project Kickoff
2 Process Mapping
3 C&E Matrix
4 Control plan review
5 MSA
6 Capability studies
7 FMEA
8 Multi-vari study
9 DOE 1
10 DOE 2
11 DOE 3
12 Control plan updates
13 SPC implementation
1/4 1/11 1/18 1/25 2/1 2/8 2/15 2/22 3/1 3/8 3/15 3/22 3/29 4/5 4/12 4/19 4/26 5/3 5/10 5/17 5/24January February March April May
OPS REVIEW
Voice of the Customer (Define)
• Did you use a cross-functional team to interview the customers?• How many customers did you interview? What market segments?• How were the customers selected?• Have you used the KJ process to sort and organize and rank their
inputs into the most significant customer desires, needs and expectations?
• Have you examined latent customer expectations?• Have you used QFD to translate significant customer desires, needs
and expectations into functional product requirements? • Have you incorporated the significant customer requirements into
rating criteria in the Pugh Concept selection matrix? • Have you used the Pugh Matrix Process to evaluate and select the
most promising design concept(s) that will meet or exceed customer expectations?
OPS REVIEW
Process Map (Measure)
Questions• Who helped develop the map and what
organizations do they represent?• Does it reflect current state or the
desired process?• Are all non value-added steps included?• What quick-hits did you find from this
effort?• What process steps does the team feel
can be eliminated or combined to reduce opportunities for scrap and increase rate?
• What characterizes an Uncontrolled and a Controlled variable?
• How do we measure the product for defects within the process?
PAPERWORK TURN STEAM ON TO DICY TANK
LOAD DMF LOAD DICY LOAD 2MI
BILL OF MATERIALS
ISO PROCEDURES
REWORK
SCALE ACCURACY
PREHEATING
LOAD ACCURACY
CLEANLINESS
RAW MATERIAL
LOAD ACCURACY
ENVIRONMENT (HUMIDITY)RAW MATERIAL
MIXER SPEED
LOAD ACCURACY
ENVIRONMENT (HUMIDITY)RAW MATERIAL
MIXER SPEED
GET PORTABLE CLEAN IF NECESSARY
LOAD SOLVENT TO PORTABLE
LOAD DRUMSTOCK TOPORTABLE
2
PROPER SIZE
REWORK
CLEANLINESS
CROSSCONTAMINATION
LOAD ACCURACY
ENVIRONMENT
RAW MATERIAL
LOAD ACCURACY
ENVIRONMENT
RAW MATERIAL
MIXER SPEED
LOAD BULK MATERIAL TOPORTABLE
2PUMP DICYSOLUTION TO PORTABLE
DIGEST STAGE BATCH TO TREATER
LOAD ACCURACY
ENVIRONMENT
RAW MATERIAL
MIXER SPEED
PUMP RATE
MIXER SPEED
FILTERING
TEMPERATURE
COMPLETE SOLUTION
TIME
MIX SPEED
VENTING
ENVIRONMENT
TIME
MIX SPEED
VENTING
ENVIRONMENT
COMPOUNDINGINPUTSTechniquesProceduresRaw MaterialsReworkEquipmentEnvironmentCleanlinessDicy Solution Temp
OUTPUTSReactivity (Gel)ViscosityCleanlinessColorHomogeneityConsistency Batch to BatchDigestion TimeTemperature
OPS REVIEW
Process Map (Measure)
Questions to Ask• Who was on your team?• How were the Customer Requirements identified?• What does the team feel are the most important Uncontrolled
KPIVs in the process?• Does this map reflect the current process or the one we want?• Where are the rework loops identified?• What are the non-value added processes?• Where are the measurement points in the process?• What does your Control Plan include at this time?• How many KPIVs did you identify per step (on average)?• What is the team going to do next?
OPS REVIEW
Cause and Effect Matrix (Measure)
Questions• Who provided inputs to the Customer
Requirements for this matrix?• What groups determined the
relationship ratings for the Inputs and Outputs?
• What method was used to determine the final relationship score?
• What actions are being taken on the top ranked Input Variables?
• Are there any quick hits that can be assigned to lower ranking Input Variables?
• Do the current Control Plans reflect the need to monitor these top KPIVs?
Rating of Importance to Customer
7 9 4 10 8 10
1 2 3 4 5 6
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Process Step Process InputTotal
1 Paint Nozzle type 9 0 9 9 9 9 3512 Paint Paint viscosity 9 9 9 9 3 3 3243 Paint Air pressure 9 3 9 9 9 3 3184 Prime Primer age 9 9 9 3 9 0 2825 Paint Paint age 9 9 9 3 9 0 2826 Paint Surface contamination 1 9 3 9 9 1 2727 Prime Air pressure 9 1 9 9 9 0 2708 Prime Nozzle type 9 0 3 9 9 0 2379 Prime Surface contamination 1 3 3 9 9 0 20810 Prime Relative humidity 1 9 9 1 9 0 20611 Paint Ambient temp 1 9 9 0 9 0 19612 Paint Surface roughness 3 1 3 3 9 3 17413 Paint Lot number 0 1 0 3 1 9 13714 Prime Surface roughness 0 1 3 3 9 0 12315 Prime Lot number 1 3 0 3 1 3 10216 Prime Ambient temp 1 3 9 0 3 0 94
Total 504
630
384
820
928
310
Lower Spec
Target
Upper Spec
Cause and Effect Matrix
This table provides the initial input to the FMEA. When each of the output variables (requirements) are not correct, that represents potential "EFFECTS". When each input variable is not correct, that represents "Failure Modes".
1. List the Key Process Output Variables2. Rate each variable on a 1-to-10 scale to importantance to the customer3. List Key Process Input Variables4. Rate each variables relationship to each output variable on a 1-to-10 scale
OPS REVIEW
Cause &Effect Matrix (Measure)
Questions to Ask• Who was on your team?• Who determined the Customer Requirements weighting?• Did you use the C&E Matrix to prioritize Process Steps to
address first?• How did the team determine the correlation values?• Does the prioritization make sense?• How many Uncontrolled Variables rated highly in the sorted
matrix?• How did the team determine the cut-off for variables to
investigate further?• Did your team include internal customer requirements?• What are your next steps?
OPS REVIEW
Measurement Systems Analysis (Measure)
Questions• What are the major sources of
measurement error?• How much measurement error
exists in comparison to the process variation? In comparison to the customer requirements?
• Is the measurement system acceptable for the process improvement efforts?
• If not, what actions do you suggest?
• How were the samples chosen?• Was the team sensitive to sub-
grouping for sample selection?
Misc:Tolerance:Reported by:Date of study:Gage name:
0
120011001000
900800700600500400300
321Xbar Chart by Operator
Sam
ple
Mea
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X=725.73.0SL=797.1
-3.0SL=654.3
0
150
100
50
0
321R Chart by Operator
Sam
ple
Ran
ge
R=37.97
3.0SL=124.0
-3.0SL=0.000
10 9 8 7 6 5 4 3 2 1
11501050
950850750650550450350
Part ID
OperatorOperator*Part Interaction
Ave
rage
123
321
120011001000
900800700600500400
Oper ID
By Operator
10 9 8 7 6 5 4 3 2 1
120011001000
900800700600500400
Part ID
By Part
%Total Var%Study Var%Toler
Part-to-PartReprodRepeatGage R&R
100908070605040302010
0
Components of Variation
Per
cent
Gage R&R (ANOVA) for Output
OPS REVIEW
Gage R&R
Source VarComp StdDev 5.15*Sigma Total Gage R&R 1727 41.558 214.021 Repeatability 1407 37.507 193.162 Reproducibility 320 17.895 92.160 Operator 320 17.895 92.160Part-To-Part 24407 156.228 804.573Total Variation 26134 161.660 832.552
Source %Contribution %Study Var %Tolerance Total Gage R&R 6.61 25.71 10.70 Repeatability 5.38 23.20 9.66 Reproducibility 1.23 11.07 4.61 Operator 1.23 11.07 4.61Part-To-Part 93.39 96.64 40.23Total Variation 100.00 100.00 41.63
Number of Distinct Categories = 5
Measurement Systems Analysis (Measure)
Questions to Ask• Who performed the MSA?• What are the %P/T and %R&R values?• What was the main source of measurement error?• What actions are necessary for improvement, and what impact will
they have?• How were the samples selected for the MSA?• What is the measurement system acceptable for use in assessing -
Process Shift or Acceptance to Specification?• What variable(s) have you completed MSA on - KPOVs or KPIVs?• What effect will this measurement system have on Capability
assessments, Multi-vari studies, and DOEs?• How is the measurement capability going to be monitored into the
future?
OPS REVIEW
Baseline (Initial) Process Capability (Measure)
Questions• What variables were
evaluated?• Are they stable?• Are there explanations for
out of control points?• How long was the process
monitored to determine stability?
• What are the largest types of variation over time - shift to shift, week to week, etc.?
250200150100500
6
4
2
0
Individual and MR Chart
Obser.
Indi
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111 1
X=1.611
3.0SL=3.349
-3.0SL=-0.1277
4.5
3.0
1.5
0.0
Mov
.Ran
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11
11
11
R=0.6537
3.0SL=2.136
-3.0SL=0.000
245235225
Last 25 Observations
2.5
2.0
1.5
1.0
Observation Number
Val
ues
40
3.34939-0.12766
Cp: 1.15 CPU: 1.37 CPL: 0.93 Cpk: 0.93
Capability PlotProcess Tolerance
Specifications
StDev: 0.579508
III
III
5.02.50.0
Normal Prob Plot
5.02.50.0
Capability Histogram
Process Capability Sixpack for sqrt_psf
0.00%
Fiscal WeekOPS REVIEW
Registration ScrapRegistration Scrap
1.00%
2.00%
3.00%
4.00%
5.00%
6.00%
Process Step/Input
Potential Failure Mode Potential Failure EffectsSEV
Potential CausesOCC
Current ControlsDET
RPN
Load DMF/DMF Load Accuracy Mischarge of DMF Viscosity out of spec 7 SOP not Followed 5
Operator Certification/ Process Audit
5 175
Steam to DICY/Scale Accuracy
Scale Not Zeroed Mischarge DMF 3 Faulty Scale 2 None 9 54
Load DMF/DMF Load Accuracy Mischarge of DMF Viscosity out of spec 7 Equipment Failure 2
Maintenance Procedure (SOP 5821)/Visual Check
3 42
Steam to DICY/Scale Accuracy
Scale > 0 Low DMF Charge 3 Water in Jacket 2 Visual Check of Jacket (SOP 5681) 4 24
Steam to DICY/Scale Accuracy
Scale Inaccurate High DMF Charge 3 Tank Hanging Up 2 Visual Check (SOP 5681) 4 24
Failure Modes Effect Analysis (Analyze)
Questions• Who helped develop the
FMEA and what organizations do they represent?
• Does the tool reflect current state or the desired process?
• What quick-hits did you find from this effort?
• What type of ranking system did you use ?
• Did you complete the actions recommended section of the tool?
OPS REVIEW
Failure Modes Effect Analysis (Analyze)
Questions to Ask• Who was on your team?• How were the Severity, Occurrence and Detection values
determined by the team?• What was the source of the rating scales for Severity,
Occurrence and Detection?• What are the top KPIVs?• What actions are being taken and by whom?• What barriers exist to completion of the top ranked items?• Are there any ‘quick fixes’ to be completed?• Were Safety items included?• How did the team decide what items to investigate further?• How did the actions affect the process performance?
OPS REVIEW
Design of Experiments (Improve)
• What significant factors and interactions exist?• How many full factorial designs were completed and why?• What methods have been utilized to optimize the process?• What actions have been taken to verify the results of the
experimentation?• How have the results been used to impact the design and
control plan?• What is the underlying model / equation that relates the
KPIVs to the KPOV(s)?• What next steps should be taken?
OPS REVIEW
Design of Experiments Proposal / Report (Improve)
Questions - Plan• Who developed and reviewed the DOE plan?
Who approved it?• What strategy was used in determining the
scope of the experiments?• How were experimental factors and levels
selected? Data?
Questions - Report/Results• What was concluded from the experiments?• What are the recommended changes based
on the studies?• What analysis techniques were used to
determine significant terms?• What percentage of the error is described by
the statistically significant terms?• How will the results be validated?
Experiment Planning Sheet
Date:_________________________ Product:______________________
Team Leader: _________________ Process(es): ___________________
Expected Start: ________________ Expected Completion:______________________________________________________________________________
Problem Statement:
Objective:
List of Experiment Parameters:
Response _________________________ Type: Quantitative QualitativeUnit of Measure ____________________Specification ______________________
Input Variables Levels Specifications
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Noise Variables Measurable?__________________________1. 2. 3. 4. 5.
Brief Outline of the Experimental Design to be used:
OPS REVIEW
-1 1
-1 1
1 1-1-1
8
7
6
5
Solvent
AirPress
Mea
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Interaction Plot for Thicknes
Design of Experiments Statistical Analysis (Improve)
Questions• What proportion of the process
variation is accounted for by the model?• How large are they in comparison to
current levels?• What interactions, if any, are important?• How will you control interaction terms?• What changes are recommended based
on the results?• What is the predicted level of the
response based on the model from the DOE?
210
1.5
1.0
0.5
0.0
-0.5
-1.0
-1.5
Effect
Nor
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Sco
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Normal Probability Plot of the Effects(response is Thicknes, Alpha = .10)
A: AirPressB: ViscC: Solvent
Fractional Factorial Fit
Estimated Effects and Coefficients for Thicknes
Term Effect Coef StDev Coef T PConstant 6.4250 0.02500 257.00 0.002AirPress 2.3000 1.1500 0.02500 46.00 0.014Visc -0.5000 -0.2500 0.02500 -10.00 0.063Solvent 0.1500 0.0750 0.02500 3.00 0.205AirPress*Visc 0.1500 0.0750 0.02500 3.00 0.205AirPress*Solvent 1.0000 0.5000 0.02500 20.00 0.032Visc*Solvent -0.0000 -0.0000 0.02500 -0.00 1.000
Analysis of Variance for Thicknes
Source DF Seq SS Adj SS Adj MS F PMain Effects 3 11.1250 11.1250 3.70833 741.67 0.0272-Way Interactions 3 2.0450 2.0450 0.68167 136.33 0.063Residual Error 1 0.0050 0.0050 0.00500Total 7 13.1750
OPS REVIEW
Designed Experiments (Improve)
• Who was on your team and what were their roles?• How did you select the factors (KPIVs) to include?• How were the levels for each factor determined?• Did you complete a screening DOE?• How did you determine the sample size requirements for each
experimental run?• What risk levels did you assume when you designed your experiment?• What did you learn from your Pilot Run?• How much variation in the response (KPOV) was due to the factors
(KPIVs) you investigated?• What actions would you recommend based on the experimental
results?• How much of your experimental budget did you consume with each
experiment?
OPS REVIEW
Final Capability Summary (Control)
Questions• What are the long and short
term process capability values?
• How does this compare to the customer’s perspective of performance?
• Is there a significant opportunity to improve beyond current levels (i.e., how large is the gap between Cp and Ppk)?
• What are the definitions of defects and opportunities?
• Are the capabilities established for KPIVs and KPOVs from the C&E?
C u sto m er R e q u irem en t
(Ou tp u t V ariab le )
M easu rem en t T ech n iq u e
% R & R o r P /T R atio
U p p er S p ec L im it
T arg etL o w er S p ec L im it
C p C p kS am p le
S iz eD a te S tatu s
F ire R etard en cyU L 700 25% 3 1.5 n a
N o D ata Ava ilab le
S elvag e E d g e C o n sis ten cy
On -lin e P h ys ica l M easu rem en t
15% 4.5 4 3 .5 1 .15 0 .85 50 S ep -95Im p ro vem en t P lan in P la ce
M em b ran e S tab ility
Ov en T e st N o n e 0.75 0 .5 n a 1 .1 0 .65 25 Au g -95M easu rem en t
S tu d y S ch ed u led
150100500
14.5
13.0
11.5
10.0
Individual and MR Chart
Obser.
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1111111
1 1
11
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X=12.64
3.0SL=14.18
-3.0SL=11.10
4.5
3.0
1.5
0.0
Mov
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1
1
1
1
1
1 1
1
R=0.5799
3.0SL=1.895
-3.0SL=0.000
155150145140135130
Last 25 Observations
13
12
11
10
Observation Number
Val
ues
16 8
14.184811.1004
Cp: 2.59 CPU: 2.18 CPL: 3.01 Cpk: 2.18
Capability PlotProcess Tolerance
Specifications
StDev: 0.514069
III
III
141210
Normal Prob Plot
141210
Capability Histogram
Process Capability Sixpack for CO2-Long
OPS REVIEW
Final Capability Summary (Control)
Questions to Ask• What variables have you conducted capability studies on?• What is the expected Short Term and Long Term performance of
that variable?• What are the suspected contributing factors to the variation in the
process?• How does the measurement system performance impact the
process capability?• What should the goals for the process capability (Cp / Cpk) be
based on the baseline data?• Over what time frame were the data taken?• How many data points / sub-groups were used to determine the
process capability?• Was the data normally distributed?• How do we handle non-normal data?
OPS REVIEW
Control Plan Summary (Control)
Questions• What control methods are
in place for KPIVs and KPOVs rated ‘high’ in the C&E matrix?
• Is SPC utilized for critical customer requirements?
• Are the measurement systems adequate for critical variables?
• Has training occurred for these control points?
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Process Step Process InputTotal
1 Paint Nozzle type 9 0 9 9 9 9 3512 Paint Paint viscosity 9 9 9 9 3 3 3243 Paint Air pressure 9 3 9 9 9 3 3184 Prime Primer age 9 9 9 3 9 0 2825 Paint Paint age 9 9 9 3 9 0 2826 Paint Surface contamination 1 9 3 9 9 1 2727 Prime Air pressure 9 1 9 9 9 0 2708 Prime Nozzle type 9 0 3 9 9 0 2379 Prime Surface contamination 1 3 3 9 9 0 20810 Prime Relative humidity 1 9 9 1 9 0 20611 Paint Ambient temp 1 9 9 0 9 0 19612 Paint Surface roughness 3 1 3 3 9 3 17413 Paint Lot number 0 1 0 3 1 9 13714 Prime Surface roughness 0 1 3 3 9 0 12315 Prime Lot number 1 3 0 3 1 3 10216 Prime Ambient temp 1 3 9 0 3 0 94
Total 504
630
384
820
928
310
OPS REVIEW
Process Step Input OutputProcess Spec
(LSL, USL, Target)
Cpk / Date (Sample
Size)
Measurement System
%R&R or P/T
Current Control
Method (from FMEA)
Who Where When Reaction Plan
Current Control Plan
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