Professional Documents
Culture Documents
Welcome to
Module 1
Administration Details
Contact Point
Introductions
Module 1
Module 2
Module 3
Module 4
Day 2
0830
Define: Step 3
Forming Team
1000
Define: Step 4
Defining
Opportunity
1230
1330
1500
Introductions
Measure: Step 8
Collecting the
data
Introduction
to DMAICR
Measure: Step 5
Need
Lunch
Lunch
Lunch
PGT Process
Measure: Step 5
Need
Measure: Step 8
Measure: Step 6
Vision
Data
Management
The DMAICR process
1830
Day 3
Define: Step 1
and Step 2
Measure: Step 7
Stakeholders
Belt Training
Introduction to
DMAICR
Off-Target
X
X
XXXXX
X
XX
X
X
X
X
X
X
X
X
X
Centre the
Process
XXX
XXX
XXX X
X XX X
On-Target
X
X
X
Reduce the
Spread
Defects
Time
Money
1 misspelled word in
13 lines of text
1 misspelled word in
7 pages of a document
1 hour wasted in
2.4 working years
1 misspelled word in
450 pages (a book!)
1 hour wasted in
160 working years
3 wasted per
1 million in assets
Factor
x11
x26
x68
dpmo
Sigma
Manual assembly
1000
Automated assembly
16
Typical s/w build
3000
Credit notes
20,000
Exchange build
160,000
Network upgrades
250,000
4.5
5.6
4.2
3.4
2.5
2.2
30
Cost of
Variation 25
%of
Sales
The Cost.
20
15
10
5
0
Sigma Level
6
Process
(Xs)
Input (Xs)
Y
Dependent
Output
Effect
Symptom
Monitor
X1 . . . XN
Independent
Input-Process
Cause
Problem
Control
Therefore...
Lots of small chunks - PROJECTS
A project must have a minimum level of potential
Does it work?
Motorola - turnaround in semiconductor
Product design
Customer service
objectives.
DMAICR has universal application across the
business.
Projects are selected based on key business
issues and will not be chosen if there is no
tangible impact on the business.
DMAICR pays for itself; returns are far greater
than investment.
Benefits are visible and traceable; focus is on
profitability.
Already Successful
Dependence on inspection and
3 sigma
rework
Reliance on trial and error
Rewarding fire-fighting behaviour
Little focus on quality
measurements
Functional silos
4 sigma
5 sigma
6 sigma
analysis
Continuous and Breakthrough
improvement
Dedicated project support
4 sigma
5 sigma
6 sigma
A philosophy
A measurement
A methodology
A standard - world class performance
Exercise 1 - Why 6
Identify the possible
benefits
to DMAICR
Identify the possible
obstacles to
DMAICR
How might you sell
DMAICR in your
division?
BeltM1D1 -26
BeltM1D1 -27
Belt Training
Introduction to
Data Analysis
Variation
X
XXXXX
X
XX
X
X
X
X
X
X
X
X
X
X
X
Centre the
Process
XXX
XXX
XXX X
X XX X
X
X
X
Reduce the
Spread
Off-Target
On-Target
Centre the
Process
Reduce the
Spread
BeltM1D1 -30
Sizing variation...
X
X
X
X
X
X
X
X
= large number
X
X
X
X
X
X
X
X
X
X
= medium number
XXX
XXX
XXX X
X XX X
= small number
BeltM1D1 -31
Reducing variation...
Reducing variation is beneficial,
but you also need to know the
limits that apply to the process
output.
These are imposed either
directly or indirectly by the
customer.
BeltM1D1 -32
Process Potential, Cp
= USL- LSL
DMAICR
Upper Specification
Limit (USL)
BeltM1D1 -33
Typical values of Cp
Approximately 2, Cp = 0.7
Approximately 3, Cp = 1.0
Approximately 4, Cp = 1.3
(for DMAICR, Cp = 2.0)
BeltM1D1 -34
X
XXXX X
XXX X
X X
X
XXX X
X
X
XX
X
XX
target
XXX
XXX
XXX X
X XX X
BeltM1D1 -35
Upper Specification
Limit (USL)
BeltM1D1 -36
Cpk = 0.8
Interpreting Cpk
Cpk ( = Cp ) = 1.3
Incapable
<1
Capable
> 1, < 1.5
Very capable > 1.5
BeltM1D1 -37
Transactional Processes
In transactional processes we often do not
Good
Defective
BeltM1D1 -38
BeltM1D1 -39
BeltM1D1 -40
NxO
= 1,000,000 x
(
(
= __________
Look up process DMAICR in
DMAICR(ST) = __________
BeltM1D1 -41
)
)(
DMAICR Scale
dpmo
(defects per
million
opportunities)
Yield %
(DMAICR
level)
Cp
308,537
69.20
0.7
66,807
93.32
6,210
99.379
1.3
233
99.977
1.7
3.4
99.99966
BeltM1D1 -42
Case study
BeltM1D1 -44
Introduction to
the DMAICR
Process
BeltM1D1 -45
BeltM1D1 -46
Requires:
BeltM1D1 -47
Project Team
OPPORTUNITIES
DEFINE
Rework
Delays
Complaints
Expediting
etc. etc.
MEASURE
ANALYSE
IMPROVE
CONTROL
REPLICATE
Performance
Customers
Profitability
User Guide
Stats Package
Tools &
Techniques
BeltM1D1 -48
OPPORTUNITIES
DEFINE
MEASURE
ANALYSE
IMPROVE
CONTROL
REPLICATE
BeltM1D1 -49
The Toolkit
Process
Analysis
Tools
Data Analysis
Tools
Change
Management
Tools
Project
Management
Tools
BeltM1D1 -50
The Toolkit
Process
Analysis
Tools
Data Analysis
Tools
Change
Management
Tools
understand and
Project
Management interpret data.
Tools
Data tools to ensure
the correct data is
collected.
Statistical Software
tool to speed the
statistical analysis.
BeltM1D1 -51
The Toolkit
Process
Analysis
Tools
Data Analysis
Tools
Change
Management
Tools
Project
Management
Tools
Teams trained to
understand and
analyse processes.
Process Analysis tools
BeltM1D1 -52
The Toolkit
Process
Analysis
Tools
Data Analysis
Tools
Change
Management
Tools
Project
Management
Tools Careful selection of
the Champion.
General tools to
ensure softer side of
change is managed.
Involvement of Major
Stakeholders.
BeltM1D1 -53
The Toolkit
Process
Analysis
Tools
Data Analysis
Tools
Change
Management
Tools
Project
management.
Management
Tools
Weekly Reviews.
Milestones and
Milestone Reviews.
Project Tracking Early
Warning System.
Templates.
BeltM1D1 -54
Resulting in
Resulting in
Resulting in ..
unsustainable solutions
another failed initiative
BeltM1D1 -55
capability 2-4
Customers happy but want
improvement
Several processes around
the company doing the same
task. Customers happy but
want improvement
No real process or very
broken process.
Customers very unhappy
DMAICR
Improvement
Project
or
DMAICR Breakthrough
Project
BeltM1D1 -56
Typical Differences
Incremental
Breakthrough
Senior Manager
Processes
Local/Support
Duration
3 - 6 months
12 - 36 months
Resources
Part-Time
Full-Time
Payback
1.5 - 3 Times
4 - 6 Times
Purpose
Resolve critical
issues
Achieve strategic
objectives
Risk
Small
The Board
Core/ Xfunctional
High
BeltM1D1 -57
Typical Approaches
Incremental
Breakthrough
Job Content
Minor mod.
Redefined
IT Systems
Minor mod.
Major mod.
Skills
Broadened
Redefined
Organisation
Existing
Re-aligned
Rewards/
Incentives
Modified
Re-evaluated
Leadership
Senior manager
The Board
BeltM1D1 -58
BeltM1D1 -59
Belt Training
Define
BeltM1D1 -60
Summary
of Starting
outcomes
Step 2*
Selecting the
Champion
Step 3
Forming the
Team
Step 4
Defining the
Opportunity
Project Champion
Project Charter
Project Plan
BeltM1D1 -61
Prioritising Opportunities
- What is done?
DEFINE
STEP 1
Purpose
Deliverables
BeltM1D1 -62
Why Prioritise
Opportunities?
DEFINE
STEP 1
BeltM1D1 -63
Prioritising Opportunities
Process
Project
Sources
How -
DEFINE
STEP 1
Who Generate
Initial List
Critical To
Quality aspects
Initial process
baseline
Gap Analysis
Prioritise on
CTQs and gaps
BeltM1D1 -64
us
to
me
th
ec
of
Vo
ice
le
op
pe
Strategic analysis
Risks
(Voice of
Shareholder).
he
Future direction
Business
Impact
Hotline (Intranet)
t
of
Share price
STEP 1
Work Areas
ice
Vo
DEFINE
Hearing Voices
- Generating the Initial List
BeltM1D1 -65
DEFINE
STEP 1
th
e
of
Shareholder).
consistently meeting
customers requirements
profitably. Therefore in
prioritising the projects we
need to select those where
the customer is least happy
with our performance.
Must listen to their voices
and convert their needs into
measurable CTQs (Critical to
Quality aspects).
le
op
pe
he
Business
Impact
(Voice of
t
of
Vo
ice
ice
Vo
cu
sto
me
DMAICR is about
Note that CTQs can also come from other stakeholders Shareholders, Employees, Society, Suppliers and Government.
BeltM1D1 -66
CTQs to Ys to Xs
ANALYSE
STEP 9
Voice of Customer
Issues
CTQs
X measures
The process and input measures
that will influence the size of Y.
Y is a function of X1, X2, X3 etc.
Y measures
The process output measures
relating to that CTQ
BeltM1D1 -67
BeltM1D1 -68
DEFINE
STEP 1
organisation.
Review and reflect with the customer and the
process team.
Refine and prioritise requirements.
BeltM1D1 -69
Kipling Checklist
I keep six honest serving-men, they taught me all I knew, their names are
What and Why and When, and How and Where and Who.
What
is done?
is the purpose of it?
and is it necessary?
Why
is it done?
is it done this way?
and is it just historic?
When
is it done?
would be better?
should it be done, before or
after?
How
is it done?
can it be done better/ easier/
more efficiently /more
effectively?
Where
is it done?
is the best place to do it?
and can it be done
somewhere else?
Who
does it?
could do it more easily/
economically?
BeltM1D1 -70
DEFINE
STEP 1
BeltM1D1 -71
Key Issue
If Im not put on
hold, I always
seem to get the
wrong department
or person
The customer
wants to be put
through quickly
to the right
person
You send me an
invoice at
different times
of the month
Consistent
monthly billing
DEFINE
STEP 1
CTQ
BeltM1D1 -72
DEFINE
STEP 1
th
e
of
Shareholder).
le
op
pe
he
Business
Impact
(Voice of
t
of
Vo
ice
ice
Vo
cu
sto
me
BeltM1D1 -73
What is meant by
base lining?
DEFINE
STEP 1
capability.
We really ought to measure this, but that
comes later
Therefore we need to estimate:
Process DMAICR
Cpk
Rolled Yield
Quality Related Cost
BeltM1D1 -74
DEFINE
STEP 1
th
e
of
Shareholder).
le
op
pe
he
Business
Impact
(Voice of
t
of
Vo
ice
ice
Vo
cu
sto
me
BeltM1D1 -75
DEFINE
STEP 1
th
e
of
Shareholder).
le
op
pe
he
Business
Impact
(Voice of
t
of
Vo
ice
ice
Vo
cu
sto
me
BeltM1D1 -76
Gap Analysis
DEFINE
STEP 1
BeltM1D1 -77
So prioritising is...
DEFINE
STEP 1
Likelihood of success
BeltM1D1 -78
Business Impact
DEFINE
STEP 1
Likelihood of
Success
High
Low
Med
Med
High
Low
Low
Med
High
Resources Required
BeltM1D1 -79
DEFINE
cr
In
High
Likelihood of
Success
s
ea
g
in
Low
i
es
D
Med
lity
bi
ra
Business Impact
STEP 1
Med
High
Low
Low
Med
High
Resources Required
BeltM1D1 -80
STEP 1
Business Impact
DEFINE
Writing a report
Quantifying the performance of a process
Reducing cycle time on a non-bottleneck process step
Resources
Likelihood of Success
BeltM1D1 -81
BeltM1D1 -82
DEFINE
STEP 2
Purpose
Deliverables
BeltM1D1 -83
DEFINE
STEP 2
Your Views..
DEFINE
STEP 2
BeltM1D1 -85
DEFINE
STEP 2
or problem.
Ideally the process owner.
Prepared to commit the necessary time and
support.
Experienced, with a good track record on
improvement issues.
BeltM1D1 -86
BeltM1D1 -87
Tell
Consult
Bargain
Work together as a team.
Participate
Facilitate
Participating
Styles
Delegate
BeltM1D1 -88
Avoid
Tell
Sell
Coach
Participating
Styles
BeltM1D1 -89
Sell
Coach
Pros:
- quick
Cons:
- check authority level
- check facts are correct
- buy-in may be limited
Consult
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -90
Tell
Sell
Coach
Pros:
- gets buy-in
Consult
Cons:
- what is the contingency?
- takes time
- smaller audiences
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -91
Sell
Coach
Pros:
- grows skill base
Cons:
- difficult to do well
- initially can be slow
Consult
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -92
Sell
Coach
Pros:
- gets involvement
Cons:
- takes time
- check balance of views
- builds expectations
Consult
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -93
Tell
Sell
Coach
Pros:
- works when other
methods fail
Consult
Cons:
- can show weakness
- know the bargaining limits
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -94
Sell
Coach
Pros:
- strengthens team
Cons:
- some team members
will expect direction
- it is easy to revert
- Problem solving
- Implementing pilot
- Implementing solution
Consult
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -95
Sell
Coach
Pros:
- very good buy-in
Cons:
- some team members
will expect direction
- facilitation is difficult
Consult
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -96
Sell
Coach
Pros:
- efficient use of team
Consult
Cons:
- some need chasing
- day job takes prime place
- result not as expected
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -97
Sell
Coach
Pros:
- essential at right time
Cons:
- knowing when to leave
- seen as lack of interest
- difficult to walk away
Consult
Bargain
Participate
Facilitate
Delegate
Avoid
BeltM1D1 -98
BeltM1D1 -99
BeltM1D1 -100
Overnight Challenge
S
S
S
S
S
Create a scheme to
help an individual to
remember the steps
that make up the
DMAICR process.
BeltM1D1 -101
Belt Training
BeltM1D1 -102