Villanova LSS Module 4 project deliverables (High level process map, VSM, SIPOC)
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SSG110LeanSixSigmaToolkitRevised5.15.203_Module3ProjectCharterComplete.xlsxProject_Charter
| DELIVERABLE MODULE 3 - PROJECT CHARTER | |||||
| Project Title: | |||||
| Black Belt | Project Champion | Executive Sponsor | MBB/Mentor | ||
| Tina Agustiady | Todd Peterson | Andy Myers | Michael Bell | ||
| Problem Statement | Business Case | ||||
| Poor quality of the Nova Point causes thick or thin product resulting in major quality variation in the product due to materials, methods, machinery, measurements, manpower or mother nature. | Business Justification consists of reducing thin/thick Issues associated on the manufacturing line and increasing first pass quality (FPQ). | ||||
| Project Goals | Project Scope | ||||
| ▪ Increase first pass quality from 91% to 99% ▪ Reduce holds by 10% | ▪ Determine improved process for thick/thin issues while implementing specifications for ingredients ▪ Determine the waste coming from the product/process ▪ Create standardized work and train all associates ▪ Determine proper preventative maintenance for equipment ▪ Determine possible equipment replacement and/or upgrades | ||||
| High Level Project Timeline | Constraints & Dependencies | Project Risks | Additional Information | ||
| Phase | Start | Finish | Production output must be maintained | • If production is slowed too much due to changes it could effect output • If the materials are brought to the line early they will start to melt before production is started | |
| Identify Value | 1-Feb | 5-Feb | |||
| Map the Value Stream | 8-Feb | 12-Feb | |||
| Create Flow | 15-Feb | 26-Feb | |||
| Establish Pull | 1-Mar | 12-Mar | |||
| Seek Perfection | 12-Mar | ongoing | |||
| Approval/Steering Committee | Stakeholders & Advisors | Project Team & SME's | |||
| Name | Organization | Name | Organization | Name | Organization |
| Todd Peterson | Nova | Todd Peterson | Nova | Tom Jones | Nova |
| Andy Myers | Nova | Andy Myers | Nova | Michelle VanHutson | Nova |
| John George | Nova | ||||
| Nancy Feller | Nova | ||||
VILLANOVA UNIVERSITY
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
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Step 1
Step 2
Step 3
Step 4
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VSM
| DELIVERABLE MODULE 4 - VSM | |
| Value Stream Map | |
| Supplier | Customer |
| Information | Information |
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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 | |||
VILLANOVA UNIVERSITY
