Project

LeanSixSigmaToolkitRevised5.15.20.xlsx

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Project_Charter

				DELIVERABLE MODULE 3 - PROJECT CHARTER
				Project Title:
				Black Belt	Project Champion	Executive Sponsor		MBB/Mentor
Problem Statement					Business Case
Project Goals					Project Scope
High Level Project Timeline			Constraints & Dependencies		Project Risks		Additional Information
Phase	Start	Finish
Identify Value
Map the Value Stream
Create Flow
Establish Pull
Seek Perfection
Approval/Steering Committee				Stakeholders & Advisors		Project Team & SME's
Name		Organization		Name	Organization	Name		Organization

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High Level Process Map

						DELIVERABLE MODULE 4 - HIGH-LEVEL PROCESS MAP
	Please add in extra processes and symbols as needed

SIPOC

DELIVERABLE MODULE 4 - SIPOC

Introduction and Instructions for SIPOC

SIPOC is an acronym that stands for supplier, input, process, output and customer

A SIPOC is a process mapping variant that for each process step identifies the inputs, the suppliers (internal or external) for those inputs, the outputs and the customers (internal or external) for that output

Using the template below, begin by filling in the "Process" column with the process steps identified in the high-level process map

Then, for each process step identify the inputs, the suppliers (internal or external) for the inputs, the outputs and the customers (internal or external) for the outputs

S.I.P.O.C. Template

Suppliers

Inputs

Process

Outputs

Customers

VILLANOVA UNIVERSITY

Start

Step 1

Step 2

Step 3

Step 4

End

VSM

	DELIVERABLE MODULE 4 - VSM
Value Stream Map
Supplier		Customer
Information		Information

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min

TOTAL

L/T

P/T

%C&A

Cause_Effect_Diagram

DELIVERABLE MODULE 5- CAUSE AND EFFECT DIAGRAM

Instructions:

STEP 1 : Define the problem. What is the product, process or service that has failed.

STEP 2 : Starting with 'Materials' or any other label, ask: is there anything about materials that

might contribute to the problem. Record it next to one of the arrows under Materials.

STEP 3 : Repeat asking "is there anything about materials that might contribute to the problem"

Problem

Record each result next to an arrow.

STEP 4 : Repeat Step 2 & 3 for each successive category.

STEP 5 : Identify the candidates that are the most likely Root Cause

STEP 6 : If further "screening" is necessary, assess the likely Root Causes using the "Impact"

and "Implement" matrix, selecting items marked 1, then 2 . . . 4 as priorities.

Pareto

	DELIVERABLE MODULE 5 - PARETO CHART
Categories	# of Occurrences
Issue 1
Issue 2
Issue 3
Issue 4
Issue 5

5-Why's

	DELIVERABLE MODULE 5 - 5 WHY'S
5-WHY ANALYSIS SHEET
		Note: Continue on separate page if 5-Whys are not enough to determine root cause.

WHY ? #1:

WHY ? #5

WHY ? #2:

WHY ? #4

WHY ? #3

TEMPORARY Date: COUNTERMEASURES

FINAL COUNTERMEASURE Name: - PERMANENT CORRECTIVE ACTION Date:

VERIFICATION: No Recurrence in Three Months? TBD Date: Single-Point Lesson? _________ Date ________ DO THE 5 WHY'S MAKE SENSE WHEN READ BACKWARD?

Waste Walk

DELIVERABLE MODULE 6 - WASTE WALK

8 Wastes/Waste Walks

Defects - Re-adjusting process parameters, reworking finished products, off spec materials

Defects

Overproduction - Making anything sooner, faster or in excess of customer requirements

Overproduction

Waiting - Waiting for raw materials, maintenance personnel, processes to finish, and instructions

Waiting

Non Utilized Talent - Workers not involved in improvement areas; input or feedback ignored. Changes without consulting workers and employees not challenged

Non Utilized Talent

Transportation - Putting products in work-in-progress areas and moving materials due to poor layout

Transportation

Inventory (Excess) - Work-in-progress, rework waiting for testing, excessive raw and finished products

Inventory

Motion (Excess) - Moving tools and people to defferent areas, excessing manual material movement

Motion

Excessive Processing - Excessive Quality checks, Performing operations not required

Excessive Processing

Waste Type

Describe the waste you saw

Root Cause Analysis

	Deliverable Module 6 Root Cause Analysis
	Root Cause Analysis (Please state your conclusions)

Kanban

DELIVERABLE MODULE 7 - KANBAN
KANBAN CARD
Part Description/Picture if Applicable	Part Number	Profile
QTY.	Lead Time	Due Date
Supplier	Location	Card #
		1 OF 2
KANBAN CARD
Part Description/Picture if Applicable	Part Number	Profile
QTY.	Lead Time	Due Date
Supplier	Location	Card #
		2 OF 2

Audit_Checklist

	DELIVERABLE MODULE 7 - AUDIT
Audit Checklist
Target Area:	Statement of Audit Objective:	Auditor:	Audit Date:
Audit Technique	Auditable Item, Observation, Procedure etc.	Individual Auditor Rating (Circle Rating)
Observation	Have all associates been trained?	YES	NO
Observation	Is training documentation available?	YES	NO
Observation	Is training documentation current?	YES	NO
Observation	Are associates wearing proper safety gear?	YES	NO
Observation	Are SOP's available?	YES	NO
Observation	Are SOP's current?	YES	NO
Observation	Is quality being measured	YES	NO
Observation	Is sampling being conducted in random fashion	YES	NO
Observation	Is sampling meeting it's sample size target?	YES	NO
Observation	Are control charts in control	YES	NO
Observation	Are control charts current?	YES	NO
Observation	Is the process capability index >1.0?	YES	NO
Number of Out of Compliance Observations
Total Observations
Audit Yield			ERROR:#DIV/0!
Corrective Actions Required
Auditor Comments

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