Designing, Controlling, and Improving Organizational Processes
Improving Processes - Exercises
description
Transcript of Improving Processes - Exercises
Six SigmaGreen Belt
-6 -4 -2 0 2 4 6
Improving Processes - ExercisesImproving Processes - Exercises
Six SigmaGreen BeltIdentifying SolutionsIdentifying Solutions
Six SigmaGreen BeltIdentifying SolutionsIdentifying Solutions
Six SigmaGreen BeltIdentifying SolutionsIdentifying Solutions
Possible Solutions?
Six SigmaGreen BeltIdentifying SolutionsIdentifying Solutions
Six SigmaGreen BeltIdentifying SolutionsIdentifying Solutions
NOT ROOT CAUSE
NOT ROOT CAUSE
Six SigmaGreen BeltIdentifying SolutionsIdentifying Solutions
Six SigmaGreen BeltCost/Benefit AnalysisCost/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?
Six SigmaGreen BeltEvaluating SolutionsEvaluating Solutions
Develop a Countermeasure Matrix for the following potential solutions:
Problem Root Causes Potential Solutions
High BloodPressure
High BMI
Exercise More
Eat Healthy Foods
High Job Stress
Reduce Alcohol Consumption
Change Job
Work Less on Current Job
Reduce Calorie Consumption
Benefit Cost Feasibility Evaluation Decision
Six SigmaGreen BeltBarriers & AidsBarriers & 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
Six SigmaGreen BeltSolution FMEASolution FMEA
The Engineering Scheduling process was modified as follows:
What could go wrong with the process changes?
Six SigmaGreen Belt
Six SigmaGreen BeltChangingChanging
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?
Six SigmaGreen BeltChangeChange
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:
Leading Change
Changing Systems & Structures
TransitionState
CurrentState
ImprovedState
Creating A Shared Need
Shaping A Vision
Mobilizing CommitmentMonitoring Progress
Making Change Last
Six SigmaGreen BeltChangeChange
Thinking about the “Six Sigma Plan” you just developed, profile your company’s Change Processes:
Profile on Change Processes
0
25
50
75
100
LeadingChange
Creatinga Shared
Need
Shapinga Vision
MobilizingCommitment
MakingChangeLast
MonitoringProgress
ChangingSystems &Structures
Profile on Change Processes
0
25
50
75
100
LeadingChange
Creatinga Shared
Need
Shapinga Vision
MobilizingCommitment
MakingChangeLast
MonitoringProgress
ChangingSystems &Structures
Six SigmaGreen BeltPin Wheel DesignPin Wheel Design
Rqmt Metric Target LSL USL Cpk
Pinwheel turns in wind of 3 fps
Rotations/ Second
8 4 - 1.5
Pinwheel time to failure (reliability)
Time to Failure (Operating minutes)
60 40 - 1
User can grasp handle with adequate clearance to pinwheel blades (safety)
Distance – Blade Tip to Top of
Hand (Inches)
6 5 - 1.5
Pinwheel handle can withstand maximum bending moment without breaking (safety)
Deflection under 2 oz. load (inches)
0.30 - 0.5 1.5
CTQs
We’ll use a simple product – a pinwheel – to help apply & tie together Process Control Planning:
PinwheelDesign
Six SigmaGreen BeltPinwheel Fabrication/Assembly DetailsPinwheel Fabrication/Assembly Details
Six SigmaGreen BeltPinwheel Fabrication & Assembly ProcessPinwheel Fabrication & Assembly Process
Process Steps1. Cut dowel rod to length (16”) (Supplier)2. Print pinwheel pattern (Supplier)3. Cut out pinwheel pattern4. Punch holes in pinwheel5. Cut slits in pinwheel6. Bend paper clip to pattern7. Tape paper clip to dowel8. Insert back button9. Insert center of pinwheel on paper clip10.Bend pinwheel wings and insert holes on
paper clip (clockwise order)11. Insert front button12.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