Key Steps in Measure phase

  1. Create/validate a value stream map to confirm current process flow
  2. Identify the outputs, inputs and process variables relevant to your project
  3. Create a data collection plan including operational definitions for all measures
  4. Create a data analysis plan
  5. Use Measurement System Analysis and Gage R&R
  6. Collect data to establish baselines
  7. Update value stream map with data
  8. Use Little’s Law to calculate lead time
  9. Perform process capability evaluation
  10. Make quick hit improvements
  11. Prepare for Measure gate review

Value Stream Map

  • Def; A process map with data (work, info, materials) including metrics
  • Mandatory tool for all teams whose mission is to speed up the process and eliminate non-value added costs.
  • Why use:
  • Identifies and quantifies waste, especially time and costs
  • Typical Data
  • Setup time
  • Processing time
  • Units in queue
  • Complexity
  • Queue time
  • When to use
  • Strategic level by mgmt. teams for identification of opportunity and project
  • An “as-is” version at the tactical level to identify and visualize the improvement opportunities
  • If your team has to assess the impact of multiple products or services
  • How to Create
  • Develop SIPOC and a swimlane flow chart
  • Identifies scope, key metrics and process steps
  • Determine what individual product, service or family you wish to map
  • Has a common flow
  • Has high volume and cost
  • Meets industry or other segmentation criteria important to the company
  • Has the biggest impact on the customer
  • Draw a process flow
  • Review process mapping symbols
  • Begin at the end of the process near the customer side, work upstream
  • Identify the main activities
  • Place activities in sequence on the map
  • Add the material flow
  • Show the movement of all the material
  • Group together material with the same flow
  • Map sub processes
  • Include any incoming inspection, and material and process testing activities
  • Add suppliers at the beginning of the process
  • Add the information flow
  • Map the information flow between activities
  • For manufacturing areas
  • Document the production orders associated with the parts through the process
  • Document the scheduling system and tracking of the parts as they move through the process
  • Document how the process communicates with the customer and supplier
  • Document how information is gathered (electronically or manual)
  • Collect process data and connect it to the boxes on the chart
  • Walk the process to observe reality
  • For each step gather the following data
  • Trigger – what starts the step
  • Setup time and processing time/unit\
  • Takt rate (rate of customer demand)
  • Percent defective and/or scrap rate
  • Number of people
  • Downtime %
  • WIP downstream and upstream
  • Costs links to IT, Warehousing, etc
  • Batch size
  • Add process and lead time data to the chart
  • Include delays (queue time), processing value added time, setup time, etc.
  • Verify Map
  • Have a non-member who knows the process review the flow and data

Review the homework from last week

Review last week assignment

Develop Charter (due 2/10)

Develop Stakeholder analysis (2/10)

Team Group rules and Roles (2/10)

Project Plan and Responsibilities (2/10)

Develop a SIPOC (2/12)

High level process map (2/12)

Team Member Biographies (2/12)

Develop a Define phase Presentation (2/15)

______

How to develop a flowchart.

  • Transportation and spaghetti
  • Diagram of physical area
  • Work from existing flow chart and draw a line between steps
  • Perform until process is completed
  • Discuss the outcome
  • Swimlanes
  • Identify the different people or job functions
  • List down the left side
  • Brainstorm the steps
  • Work thru each step in the order
  • Discuss outcome
  • Tips
  • Place most heavily used near the top
  • Use task symbols that relate to task; not just boxes
  • Communication paths are important
  • Go from left to right

Develop a VSM

  1. Demonstrate use of Visio in creating a VSM
  2. How to get there
  3. Symbol meanings
  4. Make a simple generic VSM
  5. Ordering a pizza
  1. Develop a current VSM using example data
  2. Use the data given, have each team draw a VSM on paper
  3. Use post its to create a VSM
  4. Have each group use the drawn VSM to create an e version using Visio.
  5. Use Acme Stamping example

QFD : House of Quality

Template

C2C Video 19 min 15 sec

House of Quality 6 min 45 sec

MIT 44 min 12 sec

1

Week 4Class 1