Download - 06 Process Analysis Methods
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Six Sigma
Green Belt
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Process Analysis Methods
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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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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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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.
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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
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Six Sigma
Green BeltManaging 'elia(ility
To ensure the relia(ilityof a process, wemust manage the process )ailures.
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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.
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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 $auses o) the Mode
Man
Method
MaterialsMachine
Environment
#ailure
Mode
?eective )aterial ?eective :rocessing ?eective "ssembly
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Six Sigma
Green Belt4, 0etermine 0etection A(ilities
?uring /peration
?uring &onstruction=)anuacture
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Six Sigma
Green Belt5, Prioriti6e Failure Modes7$auses
'isk :riority Cumber ':C
FA/L8'* P'9BAB/L/T: S$9'*
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Six Sigma
Green Belt5, Prioriti6e Failure Modes7$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
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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.
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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
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Six Sigma
Green Belt*xam%le o) Po=a>:o=e ty%e control