beyond cause and effect: the good, the bad and the ugly
DESCRIPTION
htttp://asqbuffalo.com About the program: While the Cause & Effect Diagram has a narrow focus in the analysis of a failure, The Good, The Bad and The Unknown Matrix goes far beyond to give you a full understanding of the process. The Good, The Bad and The Unknown Matrix is a new analysis tool that goes further than the Cause & Effect Diagram can go, being applied to different situations. This presentation will cover multiple application examples. About the Speaker: Al Germann is Senior Member of ASQ and holds CSSBB and CCT certifications. Al celebrates his 30th year working in industry and held various positions such as Quality Engineer for Metrics, Supplier Quality Engineer, Quality Manager, Project Manager and Metrologist. Employment history includes GE Transportation, Excelco/Newbrook (supplier of assemblies to the US Navy), Prestolite Electric, Woodward HSC (aerospace), and Lakeside Precision (industrial machine shop). htttp://asqbuffalo.comTRANSCRIPT
The Good, The Bad &
The Ugly UnknownBeyond the Cause & Effect Diagram
By Al Germann2011
Do you want to know everything about a process or only 1/3?
The Bad
?
Cause & Effect Diagram Results
Do you want to know everything about a process or only 1/3?
The Un-known
The Good
The Bad
Good, Bad & Unknown Matrix
The Bad
?
Cause & Effect Diagram Results
GBU Matrix influenced by 3 Quality Tools
Cause & Effect
Diagram
DMAIC
SIPOC Model
Cause and Effect diagram (aka fishbone, Ishikawa diagram)
Measurement
Methods Manpowe
rMaterials
Defect, event, output
Machines Environme
nt
General process steps: Identify the problem Brainstorm contributors into 6 categories Evaluate and prioritize items listed Select top few & develop an action plan
The C&E diagram is very focused on what went wrong,
causing the problem.
Cause and Effect Diagram
DMAIC
Define Measure Analyze Improve Control Customer Requirements CTQ Process flow
Data plan Data
collection Feedback
survey
Determine root cause
Identify gaps Find
improvement opportunities
Fully understand the process
Develop solutions
Implement improve-ments
Manage the implemented change
Add preventions to reverting back to old way
Suppliers Inputs Process
Outputs Customer
SIPOC
If something goes wrong with the output, why focus only on some of the inputs or some of the process steps?
Find The Good, Find The Bad,
Reduce the Unknowns.Fully understand the process.
“Bad”
findings
“Good” findings
The need for GBU Matrix
Adding Good & Unknown
GBU Matrix
Bad (C&E)
Good
Unknown
This helps to fully understand the
process
GBU basics
Good
•Can rule out some interactions.
•Captures good practices that can be used elsewhere.
Bad
•Captures information that leads to determining root cause (like C&E).
Unknown
•Reduces the unknowns.
Displaying the GBU Matrix
Structured format
Flexible,
variations
Display all info learned
The Good The Bad The Unknown
Materials 1.2.3.
1.2.3.
1.2.3.
Manpower 1.2.3.
1.2.3.
1.2.3.
Machine 1.2.3.
1.2.3.
1.2.3.
Methods 1.2.3.
1.2.3.
1.2.3.
Measurements
1.2.3.
1.2.3.
1.2.3.
Environment
1.2.3.
1.2.3.
1.2.3.
Basic GBU Matrix
GBU for Service or Transactions Processes
The Good The Bad The Unknown
Policies 1.2.3.
1.2.3.
1.2.3.
Procedures 1.2.3.
1.2.3.
1.2.3.
People 1.2.3.
1.2.3.
1.2.3.
Equipment 1.2.3.
1.2.3.
1.2.3.
Environment
1.2.3.
1.2.3.
1.2.3.
GBU with closed loopThe Good The Bad The
UnknownAction
Materials 1.2.3.
1.2.3.
1.2.3.
Manpower 1.2.3.
1.2.3.
1.2.3.
Machine 1.2.3.
1.2.3.
1.2.3.
Methods 1.2.3.
1.2.3.
1.2.3.
Measurements
1.2.3.
1.2.3.
1.2.3.
Environment
1.2.3.
1.2.3.
1.2.3.
Stated Condition: Dimensional nonconformance
The Good The Bad The Unknown
Action
Materials -Similar callout (sec C-7) did not have this problem-Same equipment -good history
Deformation did not repeat- not repeatable
-Why is this one worse after correction- Weld fillet size- How did it move so much
Increase tolerance on location. Submit request.- QE
Manpower -Adjustment was in right direction-Same operator
Evaluate optional over check individual.- John
Machine -Same welding equipment
Methods -Reviewed fixture & setup-good standard practice was used- position of clamps
-Sample of only 2 pieces-No in-process measurement of early deformation
- Operator look for movement during weld passes & report- Get in process measurement- Brian
Measurements
Proper measuring equipment used
Same equipment & inspector
Out of tolerance reading
Environment Good & same
Other uses
After Action
Reviews Continuous Improvement
GBU Matrix at the start of a Kaizen Event or a 5S Event
Firs
t Cause no harm S
eco
nd
Further what is good
Th
ird Improv
e what is bad
The Good The Bad The Unknown
Actions
General location
Good performing employee
Additional training is not required
Amount of floor space
Storage racks
Metal chips & drops from saw operation
Location of long length material racks
Floor clutter Some access
problem
Usefulness old inventory stock rack & mat’l
Performance rating of dust collection system
Identify cost of storage & future of old material-Jim
Review dust collection system-Billy
Schedule 5S day-John
Assign volunteers -John
GBU & 5S Project: Raw Material Receiving Area
GBU & After Action Review: Training EventThe Good The Bad The
UnknownActions
Topics covered Hands on demo Props and
samples Real word
application Presenters Holding
people’s attention
Missing best practice summary
Inspection techniques
Course note book
No comments on facility & training room
Cost impact of not training
Effectiveness of training performed
Create best practice handout-Bob
Review/improve inspection techniques coverage-Keith
Review/improve course note book-team
Estimate cost impact of not training-Cheryl
Evaluate effectiveness - Cheryl
Summary
The Cause & Effect Diagram is very good at what is does, is well proven and has a long history. However, it is very focused and may not be the best choice.
The GBU Matrix is great analysis technique for your Quality Tool Box
Summary
The GBU Matrix helps to fully understand the entire process by:
Being an effective team based tool used
for root cause analysis.
Displaying all that was discovered related
to the process, nonconformance or event.
Helps to recognize the true state of the
process, event or business KPIs.
Others: ?
Summary: Use
Immediately providing a clear
illustration in useable categories.
Closed loop system with action items.
Provides balanced and useful feedback
to work cells or teams.
Summary: Output
The GBU Matrix:
Use with or without prompting column
Applicable to manufacturing, service &
transactional processes
Use with 5S, Kaizen events or for After Action
Review, Process performance review
Summary: Options
Q&AThe Good The Bad The
UnknownAction
Materials1.2.3.
1.2.3.
1.2.3.
Manpower 1.2.3.
1.2.3.
1.2.3.
Machine1.2.3.
1.2.3.
1.2.3.
Methods 1.2.3.
1.2.3.
1.2.3.
Measurements
1.2.3.
1.2.3.
1.2.3.
Environment 1.2.3.
1.2.3.
1.2.3.
The Good The Bad The Unknown
Action
Materials 1.2.3.
1.2.3.
1.2.3.
Manpower 1.2.3.
1.2.3.
1.2.3.
Machine 1.2.3.
1.2.3.
1.2.3.
Methods 1.2.3.
1.2.3.
1.2.3.
Measurements 1.2.3.
1.2.3.
1.2.3.
Environment 1.2.3.
1.2.3.
1.2.3.