sixsigmatv · fmea process or product name: prepared by: ... c current controls d t r p n spin draw...
TRANSCRIPT
Vital Few Identification
• We must identify the Vital Few root causes from the many
probably root causes
• The Vital Few are those input and process factors (Xs)
– That can be most affected
– That most significantly influence critical to customer (CTCs) characteristics.
• Project teams may not need to prioritize when
– Only a few root causes were identified.
– It is clear which factors are the most influential on the process output.
Y = f(x1+x2+x3+x4+x5…)
Vital Few
SixSigmaTV.Net 2 Cause and Effect Matrix
C&E Matrix: Steps to Create
1. Select Key Customer Requirements (CTCs)
2. Determine a Priority Score for the CTCs
3. Enter Process Steps and Inputs from SIPOC, Swim-Lane Map, Fishbone
4. Rate the Correlation of Steps to CTCs
5. Cross Multiply Correlation Values with Priority Factors and Sum for each Input
6. Pareto the Results
7. Update SIPOC and Analyze Further
SixSigmaTV.Net 3 Cause and Effect Matrix
C&E Matrix: Example
• A manager at a local diner wants to improve customer satisfaction with the coffee they serve
• The team has completed a process map and they are ready to create a C&E matrix to identify the inputs that have the largest impact on customer satisfaction
• The team chose 3 aspects of customer satisfaction to focus upon: temp, taste and strength
SixSigmaTV.Net 4 Cause and Effect Matrix
Coffee Service Process Map
Inputs Outputs Inputs Outputs
• Hot Water
• Soap
• Scrubber
• Clean Carafe
• Cold Water
• Measuring
Mark
• Full
Carafe
• Filter
• Maker w/Filter
• Fresh Coffee
• Dosing Scoop
• Maker w/Filter &
Coffee
• Brewing Coffee
• Clean Carafe
• Dirty Water
• Wet Scrubber
• Full
Carafe
• Filled Maker
• Empty
Carafe
• Maker
w/Filter
• Maker w/Filter &
Coffee
• Operating Maker
• Heat
• Brewed Coffee
• Hot Coffee
• Customer
• Order
• Size
Specification
• Complete
Order
• Hot Coffee
• Cup
• Filled Cup
• Customer
• Cream
• Sugar
• Amount
Desired
• Complete Order
• Money
• Coffee Delivery
• Complete
Order
• Filled Cup
• Customer
Reply
• Amount
Specified
• Complete
Order
• Make Change
• Temperature
• Taste
• Strength
• Smile
• Happy
Customer
Pour Coffee
into Cup
Offer
Cream &
Sugar
Complete
Transaction
Say Thank
You
Receive
Coffee
Order
Clean Carafe
Fill Carafe
w/Water
Pour Water
into Maker
Place Filter in
Maker
Put Coffee
in Filter
Select
Temperature
Setting
Turn Maker On
SixSigmaTV.Net 5 Cause and Effect Matrix
Create a C&E Matrix
Step 1: Select Key Customer Requirements
Temp of
Coffee Taste Strength Process Outputs
Importance
Process Steps Process Inputs TotalCorrelation of Input to Output
Process Outputs – CTCs
SixSigmaTV.Net 6 Cause and Effect Matrix
Step 2: Determine Priority Score
Temp of
Coffee Taste Strength Process Outputs
8 10 6 Importance
Process Steps Process Inputs TotalCorrelation of Input to Output
Importance Rating A higher score indicates the output is more important to
the customer
Create a C&E Matrix
SixSigmaTV.Net 7 Cause and Effect Matrix
Step 3: Enter Process Steps
Temp of
Coffee Taste Strength Process Outputs
8 10 6 Importance
Process Steps Process Inputs Total
Clean Carafe
Fill Carafe with Water
Pour Water into Maker
Place Filter in Maker
Put Coffee in Filter
Turn Maker on
Select Temp Setting
Receive Coffee Order
Pour Coffee into Cup
Offer Cream and Sugar
Complete Transaction
Say Thank You
Correlation of Input to Output
Process Steps
Create a C&E Matrix
SixSigmaTV.Net 8 Cause and Effect Matrix
Step 4: Add Process Step Inputs and Rate Impacts
on CTCs
Temp of
Coffee Taste Strength Process Outputs
8 10 6 Importance
Process Steps Process Inputs Total
Clean Carafe Hot Water 0 6 3 78
Fill Carafe with Water Cold Water 3 6 9 138
Pour Water into Maker Full Carafe 3 9 9 168
Place Filter in Maker Filter 0 3 3 48
Put Coffee in Filter Coffee 0 9 9 144
Put Coffee in Filter
Coffee Maker w/
Filter 3 1 0 34
Put Coffee in Filter Dosing Scoop 9 3 3 120
Receive Coffee Order Order 0 0 0 0
Pour Coffee into Cup Hot Coffee 9 6 6 168
Offer Cream and Sugar Cream 0 6 6 96
Complete Transaction Money 0 0 0 0
Say Thank You Coffee Delivery 0 0 0 0
Correlation of Input to Output
Process Step Correlation Scores A higher number indicates stronger correlation
Create a C&E Matrix
SixSigmaTV.Net 9 Cause and Effect Matrix
Step 5: Calculate Totals
Temp of
Coffee Taste Strength Process Outputs
8 10 6 Importance
Process Steps Process Inputs Total
Clean Carafe Hot Water 0 6 3 78
Fill Carafe with Water Cold Water 3 6 9 138
Pour Water into Maker Full Carafe 3 9 9 168
Place Filter in Maker Filter 0 3 3 48
Put Coffee in Filter Coffee 0 9 9 144
Put Coffee in Filter
Coffee Maker w/
Filter 3 1 0 34
Put Coffee in Filter Dosing Scoop 9 3 3 120
Receive Coffee Order Order 0 0 0 0
Pour Coffee into Cup Hot Coffee 9 6 6 168
Offer Cream and Sugar Cream 0 6 6 96
Complete Transaction Money 0 0 0 0
Say Thank You Coffee Delivery 0 0 0 0
Correlation of Input to Output
Process Outputs - Totals
Create a C&E Matrix
SixSigmaTV.Net 10 Cause and Effect Matrix
132 22 24 34 36 36 52 120 144 144
3.0 3.2 4.6 4.8 4.8 7.0 16.1 17.7 19.4 19.4
100.0 97.0 93.8 89.2 84.4 79.6 72.6 56.5 38.7 19.4
700
600
500
400
300
200
100
0
100
80
60
40
20
0
Defect
Count
Percent
Cum %
Fill Carafe
with Water Put
Coffee in
Filter
Offer
Cream &
Sugar
Select
Temperature
Setting
Pour
Coffee
into Cup Clean
Carafe
Place Filter
in Maker
Turn
Maker
On Complete
Transaction Others
Cou
nt
Per
cent
Step 6: Create Pareto Chart
Step 7: Update SIPOC and Analyze Further (as necessary)
Create a C&E Matrix
SixSigmaTV.Net 11 Cause and Effect Matrix
Linking the C&E Matrix to Other Lean Six Sigma Tools
FMEA
Process or
Product Name:Prepared by:
Responsible: FMEA Date (Orig) ______________ (Rev) _____________
Process
Step/Part
Number Potential Failure Mode Potential Failure Effects
S
E
V Potential Causes
O
C
C Current Controls
D
E
T
R
P
N
Spin Draw
Process
Fiber Breakouts Undersized package, High SD
panel-hours lost 2Dirty Spinneret
8Visual Detection of Wraps and
broken Filaments 9 144
5Filament motion
2Visual Sight-glass
8 80
8Polymer defects
2Fuzzball Light
9 144
0
Process/Product
Failure Modes and Effects Analysis
(FMEA)
Key Inputs are explored
C&E Matrix
Rating of
Importance to
Customer
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Process Step Process Inputs Total
1 0
2 0
3 0
4 0
5 0
The Key Inputs are evaluated
Control Plan Summary
Product: Core Team: Date (Orig):
Key Contact:
Phone: Date (Rev):
Process Process Step Input Output
Process
Specification (LSL,
USL, Target)
Cpk /Date Measurement
Technique
%R&R
P/T
Sample
Size
Sample
Frequency
Control
MethodReaction Plan
DICY Turn Steam on Scales
Accuracy
DMF Load DMF DMF Load
Accuracy
DMF Load DMF DMF
Cleanliness
DICY Load DICY DICY Envir.
Factors
DICY Load DICY DICY Load
Accuracy
DICY Load DICY DICY Raw
Materials
DICY Load DICY DICY Mixer
Speecd
DMF Load DMF DMF Raw
Materials
DICY Turn Steam on Preheating
DICY TK
Operational Excellence
Control Plan
SixSigmaTV.Net 12 Cause and Effect Matrix