Analyse Requirements

Module 2 deliverables

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Affinity Diagram
Main Effect

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Organize the Causes

Method 1 Cause Relations

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Cause Relations
Root Cause Main Issue 3

Main Issue 1

Root Cause
Main Issue 2

Main Header Root Cause

Main Issues (Primary causes) are with the most arrows going IN. A arrow is linked from the primary causes to the centre. The root cause/s are those that have the most arrows going OUT

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Organize the Causes

Method 2 Fault Tree Analysis

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Minimum 3 levels of Causes. First level is from Affinity diagram (Brainstorming)

For Causes with more than 3 levels, start from the back to find the Cause Failure - Effect

First: Brainstorm freely. (Do not start with FTA) Second: Affinity diagram Third: Arrange First level causes in FTA

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Root Causes
The cause/s are developed further by doing a Fault Tree Analysis (FTA).
Root Causes

Potential X

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Visualize the Causes

Method 1 Ishikawa Diagram

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Ishikawa Diagram
A useful tool for visualizing root causes is the Ishikawa (fishbone) diagram. There are a variety of ways to use it. It is primarily a tool for organizing information to establish and clarify the relationships between an effect and its main causes.
CAUSES Problem Statement

EFFECT

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Ishikawa Diagram
The Ishikawa diagram identifies the potential root cause(s) of the problem so that collective actions can be taken to eliminate their recurrence. It assists in reaching a common understanding of the problem and exposes the potential drivers of the problem.

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Ishikawa analysis
The Ishikawa starts with taking the causes already listed. Each set of causes is linked and diagnosed to reach 5 levels of analysis wherever possible. A primary cause alone is not acceptable

Primary Level 3 Level 5 Level 4 Level 2 Header

Complete Ishikawa analysis

Header 3 Header 2 Header 1
1.1 1.1.1 1 1.2.1 1.2

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This is ROOT cause

Potential X OR Top Occurrence

Header 6

Header 5

Header 4

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Select the Main Root Causes

Method 1 Constant, Noise, Experimental (CNX)

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Constant, Noise, Experiment

Causes CNX Details
Header

Possible Solution

 Show quick wins

Insert Kaizen Activity (if any)

Analyze

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Analyse Requirements
Module 3 deliverables

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Analyze

Sample Data Collection

Based on each ME, sample data is collected for each root cause. For example: ME 1 Discrete or Continuous
Root Causes RC 1 RC 2 Type of Data Continuous/Discrete

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Analyze Continuous

1. 2. 3. 4.

Pareto Test for proportions ANOVA Main Effects Plot

1. 2. 3. 4.

Test for Means Test for Variances Correlation Regression

ME
1. Test for proportions 2. ANOVA 3. Chi Sq (Categories Only) 1. 2. 3. 4. 5. Test for Means Test for Variances Correlation Regression ANOVA

Discrete

Discrete

RC

Continuous
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Confirm main root causes

Main Effect ME 1 Main Root Causes RC 1
RC 2 RC 3 RC 4 RC 5 ME 2 etc RC 1 etc

Analyze

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Possible innovative solutions criteria

I Invention
A Add Value M Maximize available resources W Win Win I Integrated S Savings E Extensive
The Search light for Creative and Innovative solutions I - Invention
The solution derived through the process of thinking (PDCA/DMAIC) is new to the organization. It is a first attempt by anyone or group. The idea may have been inspired by developments and applications in technology outside the organization. It is an invention, when the team or circle modifies, customizes or improves on ideas from external sources. The key concern is that the method, product or process is new to the organization.

A Add Value
The solution eliminates or reduces physical strain and effort in creating a method or product that impact on desired output. The new value is derived when physical, bodily movements and strain are replaced by knowledge-based work, relieves fatigue and physical concentration in obtaining the desired output.

M Maximize use of available resources

The technologies in use to produce the output and the resources available the organization are used differently. More is obtained from the mix of resources that go into making the desired product or service.

W Win-Win results for the Stakeholders

The stakeholders benefit from the new solution. The customers, suppliers, public/community, organization and team/circle members obtain tangible and intangible benefits from the solution.

I Integrated
The solution compliments and adds value to other processes, systems, and methods in use in the organization. The solution positively reinforces the standards of performance in other work processes and methods.

S Savings
The solution saves time, money and resources. Peoples skills and performance is upgraded and the effort and energy is diverted to learning and continuous improvement activities.

E Extensive
The application of the solution is extended to other organizations, departments and work places. The solution becomes a benchmark for others in the industry and enables the transfer of the new technology to other environments. The organization achieves the best practice ideals.

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Develop Solutions for Main Root Causes

Analyze

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XY Matrix I AM WISE
Project: Date: 1 Output Variables Invention (Y's) Output Rating 1 to 10 Input Variables (X's) ME 1 RC1 SOLUTION A ME 1 RC1 SOLUTION B ME 1 RC1 SOLUTION C ME 1 RC2 SOLUTION A ME 1 RC2 SOLUTION B ME 1 RC2 SOLUTION C 0.5 2 3 4
WIN-WIN

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MAIN EFFECT 1

5
Integrated

6
Savings

7
Extensive

Maximize Add Value Available Resources

1.5

1 Rating 0 0 0 0 0 0 % 0.00 0.00 0.00 0.00 0.00 0.00

Association Table

0.00
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Validation of Selected Solutions

Project: Date: 1 Output Variables (Y's) Output Rating 1 to 10 Input Variables (X's) ME 1 RC1 SELECTED SOLUTION CCR 1 2 CCR 2 3 CCR 3 1 4 CCR 4 2 5 CCR 5 2 Rating 0 0 ME 1 RC2 SELECTED SOLUTION 0 0 ME 1 RC3 SELECTED SOLUTION 0 0 ME 1 RC4 SELECTED SOLUTION 0 0 % 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
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MAIN EFFECT 1

2 3 Association Table

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Force Field Analysis

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PDPC
Process Negative Positive Decision Decision Decision Process Decision Negative

Positive Decision

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Solution Implementation plan

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Gantt chart

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