mod 5 01 cause&effect mar 02

8/12/2019 Mod 5 01 Cause&Effect Mar 02

1/20

1 Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Cause and Effect MatrixBlack Belt Training

Module #5


2/20


The Breakthrough Strategy

Define BB Works with Management1 Select Output Characteristic and identify

key process input and output variables

Define !erformance Standards

" #alidate Measurement System

$ %stablish !roduct Capability

& Define !erformance Ob'ectives

( )dentify #ariation Sources

* Screen !otential Causes

+ Discover #ariable ,elationships

- %stablish Operating .olerances

1/ #alidate Measurement System

11 Determine !rocess Capability

1 )mplement !rocess Controls

Measure

0nalye

)mprove

Control

Characterie

Optimie


3/20


Measurement Phase

Project efinition!" Prolem escri$tion %&uthori'e($$t)" Project Metrics %Metrics(xls)

Process Ex$loration!" Process *lo+ iagram" C,E Matrix- P*ME&- *ishone iagrams

" ata collection system Measurement System%s) &nalysis %MS&)!" &ttriute . /ariale 0age Studies

Ca$aility &ssessment %on each 1)" Ca$aility %C$k- P$k- s 2e3el- P4- T1)

0ra$hical , Statistical Tools

Project Summary" Conclusion%s)" 6ssues and arriers" 7ext ste$s

Com$leted 82ocal Project e3ie+9


4/20


escri$tion! Cause and Effects Matrix

:ill em$hasi'e the im$ortance of understanding the customerre;uirements

4sed to relate and $rioriti'e s are scored as to im$ortance to the customer

s are scored as to relationshi$ to out$uts esult! Pareto of s +hich can e used as a starting $oint in

the e3aluation of the *ME& and control $lans

This tool +ill allo+ everyonein3ol3ed +ith a $rocess to agreeon the out$uts that are critical to the $roduct and . or customer

/ia numerical ranking- this matrix +ill allo+ your team to assigna le3el of im$ortance to each out$ut 3ariale

Through association- the matrix +ill allo+ a team to numericallyassess the effect of each < on each 1

This is the teams first sta at determining2 3 f 4 5 6


5/20


Process Ma$ to e 4sed in Exam$le

Burger 0ssembly)7!8.S O8.!8.S

Bun

Burger

Condiments

Cooking time

Cooking Tem$

Packaging

Procedure

&$$earance

Taste

Smell

*reshness

ConsistencyTem$erature

Cook Burger &ssem#le :ra$ Store Sell

BurgerCook Tem$

Cook Time

BurgerBun

Condiments

&ssy( Procedure

&ssem( Burger:ra$$er

:ra$ Procedure

?eat 2am$Store Time


6/20


Ste$ @) Exam$le

ating of

6m$ortance to

Customer

@ A 5 D E F G @H @@ @A @ @ @5

Process 6n$uts &$$earance

Taste

Smell

*reshness

Consistency

Tem$erature

Total

@ H

A H

H H

5 H

D H

E H

Cause and %ffect

Matri5

19 :ist key

outputs 42;s6

STEP @ 2ist the out$ut 3ariales %1=s) along the to$ section of the matrix(These are out$uts +hich the team and . or the customer deem to e im$ortant(These may e a suset of the list of 1=s identified on the $rocess ma$(


7/207 Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Ste$ A)

ating of

6m$ortance to

Customer

E @H F @H E F

@ A 5 D E F G @H @@ @A @ @ @5


Taste

Smell

*reshness

Consistency

Tem$erature

Total

@ H

A H

H

H

5 H

D H

E H

F H

Cause and %ffect

Matri5

STEP A ank each out$ut numerically using an aritrary scale%$ossily @I@H)( The most im$ortant out$ut recei3es the highest numer(

9 ,ank outputs

by importance to

Customer


8/20


@ A 5 D E F G @H @@ @A @ @ @5


Taste

Smell

*reshness

Consistency

Tem$erature

Total

@ Bun H

A Burger H

Cook Time H

Cook Tem$ H

5 Condiments H

D &ssem#ly

Procedure H

E &ssem#ledBurger

H

F :ra$$er H

G :ra$

Procedure H

@H?eat 2am$

Tem$ H

@@ Storage Time H

"9 :ist the

key inputs

STEP

6dentify all $otential

in$uts or causes

%


9/20


Ste$ ) 0uidelines

1ou are ready to 8correlate9 customer re;uirementsto the $rocess in$ut 3ariales

&ssignment of the scoring takes the most time

To a3oid this- s$ell out the criteria for each score

%exam$les)!" H J 7o correlation

" @ J The $rocess re;uirement only remotely affects the

customer re;uirement

" J This in$ut 3ariale has a moderate effect on thecustomer re;uirement

" G J This in$ut 3ariale has a direct and strong effect on the

customer re;uirement


10/20


ating of

6m$ortance to

Customer

E @H F @H E F

@ A 5 D E F G @H @@ @A @ @ @5


Taste

Smell

*reshness

Consistency

Tem$erature

Total

@ Bun G G G 5

A Burger E D F F F G

Cook Time E E @ F F AFE

Cook Tem$ E D @ F E ADG

5 Condiments @ @ @ @ @ @ 5H

D&ssem#ly

ProcedureG @ @ F D AA5

F :ra$$er 5 @ @ D @ D @DF

G:ra$

Procedure5 @ @ 5 @ @ @@F

@H?eat 2am$

Tem$@ @ @ F D G A@G

@@ Storage Time G F G G 5 DF

$9 Correlate


11/20


ating of6m$ortance to

Customer

E @H F @H E F

@ A 5 D E F G @H @@ @A @ @ @5


Taste

Smell

*reshness

Consistency

Tem$erature

Total

@ Bun G G G 5

A Burger E D F F F G

Cook Time E E @ F F AFE

Cook Tem$ E D @ F E ADG

5 Condiments @ @ @ @ @ @ 5H

D&ssem#ly

Procedure

G @ @ F D AA5

F :ra$$er 5 @ @ D @ D @DF

G:ra$

Procedure5 @ @ 5 @ @ @@F

@H?eat 2am$

Tem$@ @ @ F D G A@G

&9 Cross=

multiply and

prioritie

We now start getting

a feel for which

variables are most

important to

e5plaining variationin the outputs9

Ste$ 5)

STEP 5 4se the totals column to analy'e and $rioriti'e +here to focus youreffort +hen creating the $reliminary *ME&(


12/20


ating of

6m$ortance to

Customer

E @H F @H E F

@ A 5 D E F G @H @@ @A @ @ @5


Tas

te

Sm

ell

*re

shness

Consistency

Tem

$erature

Total

@ Storage time G F G G 5 DF

Bun G G G 5

Burger E D F F F G

E Cook Time E E @ F F AFE

D Cook tem$ E D @ F E ADG

F&ssem#ly

ProcedureG @ @ F D AA5

G?eat 2am$

Tem$@ @ @ F D G A@G

A :ra$$er 5 @ @ D @ D @DF

@H:ra$

Procedure

5 @ @ 5 @ @ @@F

Exam$le I Pareto of s

Storage time-

un and urger

in$uts are the

most im$ortant(

:e can no+e3aluate the

control $lans for

these s

We have sorted on the cross=multiplied numbers and find that>


13/20


The Method

STEP @ 2ist the out$ut 3ariales %1=s) along the to$ section of thematrix( These are out$uts +hich the team and . or thecustomer deem to e im$ortant( These may e a suset ofthe list of 1=s identified on the $rocess ma$(

STEP A ank each out$ut numerically using an aritrary scale

%$ossily @I@H)( The most im$ortant out$ut recei3es thehighest numer(

STEP 6dentify all $otential in$uts or causes %


14/20


2inks To Kther Tools

ating of

6m$ortance to

Customer

G G @ H @H G A D

@ A 5 D F G @H @ @ @ A @ @ @ 5

Process 6n$uts 0elTime

/iscosity

Cleanliness

Color

?omogeneity

Consistency

igetsTime

Tem$erature

Solids

Total

@Scales

&ccuracyG F A @ @ G @ @ F A@

APreheating

6C1 TL@ @ @ @ @ @ @ @ @ D5

M* 2oad

&ccuracy F @ @ @ F @ F A55

M*

Cleanliness@ @ A @ A @ @ @ @H5

5M* a+

Materials@ @ @ @ @ A @ @ @

D 6C1 2oad&ccuracy

G @ @ @ G @ @ A ADG

6C1 En3ir(

*actorsF 5 @ @ F @ @ A A

F6C1 a+

MaterialsF 5 @ @ @ G @ @ A AA

G6C1 Mixer

S$eecd@ @ @ @ @ @ @ @ @A5

C?% Matri5

@M%0

Process or

Product7ame!Pre$ared#y!

es$onsi#le! *ME& ate %Krig) %e3)

!rocess

StepA!art

7umber !otentia l @a ilure Mode !otentia l @a ilure%ffects

S

%

# !otentialCauses

O

C

C Current Controls

D

%

.

,

!

7

S$in ra+

Process

* i# er B re akou ts 4 nd er si 'ed $ ackag e- ? i gh S

$anelIhours lost Airty S$inneret

F/isualetection of:ra$s and

#roken *ilaments G @

5*ilament motion

A/isualSightIglass

F FH

FPolymer defects

A*u''#all 2ight

G @

H

!rocessA!roduct

@ailure Modes and %ffects 0nalysis

4@M%06

Capability Summary

Customer,eBuirement

4Output #ariable6

Measurement

.echniBue

,?, or!A.

,atio

8pper

Spec

:imit

.arget

:ower

Spec

:imit

Cp CpkSample

Si1eDate 0ctions

el .ime

#iscosity

Cleanliness

Color

Eomogeneity

Consistency

Digets .ime.emperature

Solids

Fey !rocess Output #ariable

Capability Status Sheet

.he Fey Outputs are

listed and evaluated9

Control !lan SummaryProduct! Core Team! ate %Krig)!

LeyContact!

Phone! ate %e3)!

!r oc es s !r oc es s Ste p ) np ut O ut pu t

!rocess

Specification4:S:G

8S:G.arget6

CpkADateMeasurement

.echniBue

,?,

!A.

Sample

Si1e

Sample

@reBuency

Control

Method,eaction!lan

D )C 2 . ur n St ea m o n Scales

&ccuracy

DM@ :o ad DM@ M*2oad

&ccuracy

DM@ :o ad DM@ M*

Cleanliness

D) C2 : oa dD )C2 6C1 En3ir(

*actors

D) C2 : oa dD )C2 6C1 2oad

&ccuracy

D) C2 : oa dD )C2 6C1 a+

Materials

D) C2 : oa dD )C2 6C1 Mixer

S$eecd

DM@ :o ad DM@ M*a+

Materials

D )C 2 . ur n St ea m o n Preheating

6C1 TL

Control !lan

.he Fey )nputs are

evaluated

Fey )nputs are e5plored

Outpu

ts )nputs


15/20


Customer

,eBuirement

4Output #ariable6

Measurement

.echniBue

,?, or !A.

,atio

8pper

Spec

:imit

.arget

:ower

Spec

:imit

Cp CpkSample

SieDate 0ctions

.emperature Thermometer @HN @5H deg @H deg @H deg A @(DE H A.AE.HA

.aste 2ikert Scale

Smell

@reshness

Consistency0ppearance

.he purpose of this worksheet is to guide actions needed to get

statistical capability data9 .he form addresses both the measurement

systems and the process capability9 0ny blank spaces in the form

need to be addressed by actions9

Ca$aility Summary


16/20


Control Plan Exam$le

Product! ?am#urger Core Team! Ted- Bill- Mary ate %Krig)! A.AE.HA

L ey Cont ac t! Chris

Phone! EAGE ate %e3)!

!rocess !rocess Step )nput Output

!rocess

Specification

4:S:G 8S:G

.arget6

Cpk ADateMeasurement

.echniBue

,?,

!A.

Sample

Sie

Sample

@reBuency

Control

Method

,eaction

!lan

Eamburger

0ssembly

Storage Eeat :amp .emp 1"/ = 1&/ deg 19(* A =*=/ .hermometer 1/ 1// 1Aday


17/20


Ouestions aout 6nitial Control Plan 6tems

Standard K$erating Procedures" o they exist" &re they understood" &re they eing follo+ed" &re they current" 6s o$erator certification $erformed" 6s there a $rocess audit schedule

Controllale s" ?o+ are they monitored" ?o+ often are they 3erified" &re o$timum target 3alues and s$ecifications kno+n

" ?o+ much 3ariation is there around the target 3alue" ?o+ consistent are they Kther Ouestions

" ?o+ often is an < out of control" :hich s should ha3e control charts


18/20


&$$roaching the C,E Matrix %CT Matrix)

Project Selection" Phase 6

Place the usiness metrics %CT>s eli3ery- Cost- Ouality)across the to$ of the matrix and rank

Place the $roducts do+n the left side of the matrix

Correlate each $roduct to each CT

Pareto the $roducts

" Phase 66

Start a ne+ C,E Matrix +ith Products across the to$ and then$lace the $rocesses that su$$ort these $roducts do+n the side

Correlate each $rocess to each $roduct(

This identifies a $otential $roject" Phase 666

Place the $rocess out$uts across the to$ of the matrix andrank

Place the in$uts do+n the side of the matrix starting +ith thefirst $rocess ste$ and mo3ing to the last


19/20


Coffee Exercise

Work in teams to develop C&E matrix.

Rate inputs as a function of each output.

Discuss how you would get customer importanceratings

!areto your results.

Report out top three inputs.


20/20


Coffee Exercise C,E Matrix

,ating of

)mportance to

Customer

@ A 5 D E F G @H @@ @A @ @ @5

&rom

a

Taste

Tem$erature

Color

Total

!rocess )nput

@ :ater

A Coffee

*ilter

?eat

5 Measuring cu$

D Bre+ing Method

E

F

G

@@

@A

@

@

@5

Cause and %ffect

Matri5

mod 5 01 cause&effect mar 02

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