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Improving Processes - Exercises

-6. -4. -2. 0. 2. 4. 6. Improving Processes - Exercises. Identifying Solutions. Identifying Solutions. Identifying Solutions. Possible Solutions?. Identifying Solutions. Identifying Solutions. NOT ROOT CAUSE. NOT ROOT CAUSE. Identifying Solutions. Cost/Benefit Analysis.

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Improving Processes - Exercises

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  1. -6 -4 -2 0 2 4 6 Improving Processes - Exercises

  2. Identifying Solutions

  3. Identifying Solutions

  4. Identifying Solutions Possible Solutions?

  5. Identifying Solutions

  6. Identifying Solutions NOT ROOT CAUSE NOT ROOT CAUSE

  7. Identifying Solutions

  8. Cost/Benefit Analysis • You are considering buying a new Ford Escape • The Escape is available with two power plants: • Standard Gasoline Engine ($21,000, 24 mpg - city) • Hybrid-Gas/Electric Engine ($27,000, 36 mpg - city) • The average price of gas is $2.35/gallon. • Without considering the cost of money or differences in maintenance expenses, how long would it take to pay-back the higher initial cost of the car through improved gas mileage?

  9. Evaluating Solutions • Develop a Countermeasure Matrix for the following potential solutions: Problem Root Causes Potential Solutions Exercise More High BMI Eat Healthy Foods High Blood Pressure Reduce Alcohol Consumption Change Job High Job Stress Work Less on Current Job Reduce Calorie Consumption

  10. Barriers & Aids • For the countermeasures of “eat healthy food” & “exercise more often” develop a barriers & aids analysis: Current State: High Blood Pressure Future State: Low Blood Pressure

  11. Solution FMEA • The Engineering Scheduling process was modified as follows: • What could go wrong with the process changes?

  12. Changing • Part 1 – Recall a change that was successful in your company. Why was it successful? What factors contributed to it’s success? • Part 2 - Recall a change that was not successful in your company. Why was it not successful? What factors contributed to it’s not being a success?

  13. Leading Change CurrentState Making Change Last Creating A Shared Need ImprovedState Shaping A Vision Monitoring Progress Mobilizing Commitment TransitionState Changing Systems & Structures Change • Suppose your company management decided that “Six Sigma” was needed to drive necessary improvements in processes and competitiveness. • Apply the elements of change to help them build a “plan” for introducing and implementing Six Sigma:

  14. Change • Thinking about the “Six Sigma Plan” you just developed, profile your company’s Change Processes:

  15. Pin Wheel Design We’ll use a simple product – a pinwheel – to help apply & tie together Process Control Planning: CTQs Pinwheel Design

  16. Pinwheel Fabrication/Assembly Details

  17. Pinwheel Fabrication & Assembly Process • Process Steps • Cut dowel rod to length (16”) (Supplier) • Print pinwheel pattern (Supplier) • Cut out pinwheel pattern • Punch holes in pinwheel • Cut slits in pinwheel • Bend paper clip to pattern • Tape paper clip to dowel • Insert back button • Insert center of pinwheel on paper clip • Bend pinwheel wings and insert holes on paper clip (clockwise order) • Insert front button • Bend over tip of paper clip to secure button • Materials: • Pinwheel pattern printed • Dowel rods (48”) • Paper Clips (large) • Shirt Buttons • Tape • Tools: • Scissors • Hole Punch • Needle-Nose Pliers • Ruler

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