9 steps on analysis


Kaizenex offers consulting and

training services to help your

organization achieve Operational

Excellence, supporting your

Continuous Improvement and

Lean and Six Sigma initiatives.

Elmer BuscadoFounder / Lean AdvisorEmail : [email protected] : +639178557722Web : www.kaizenex.com


Step 1: Problem Statement;

Step 2: Find the root cause/s by

asking Why 5 times.

Step 3: State the practical theory

Step 4: Develop Hypothesis Test

Statement.

Step 5: Verify Hypothesis or

Theory.

Step 6: Confirm the True Cause

and reject failed theories.

Step 7: Propose Solution

Step 8: Assign who will be responsible

Step 9: Plan date of Execution or

completion.


Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 & 9


Problem Statement

1st WHY 2nd Why 3rd Why 4th Why 5th Why

Root Cause

INCONSISTENT TALLY SHEET

REPORT

No Time to Mark the Tally

Sheet

Too Many Orders

Too Many Customers

Lack of Crew On rest DayGov’t

Regulations

Wrong InputDo Intelligent

GuessingLost Track of

CountBatch Marking

Inefficient Crew

Some Crew Neglect to

Mark

It is Weekend


Problem Statement

1st WHY 2nd Why 3rd Why 4th Why 5th Why

Root Cause


REPORT

Pen is not immediately

available

Keep in the Drawer

Common Practice

Not Following Procedure

Not TrainedNo visual aid

availableNo one Made

one

Forgot the procedure

No visual aid available

No one Made one

No One is Checking

No one is assigned to

check

Actual Process are inadequate

Marking is not integrated to serving Cycle.

Unable to Mark Tally

Sheet on Time

Form is Not Immediately

Available

Keep in the Folder / Nod

Defined Location

Common Practice


X1: More inconsistency generated as the demand increases.

X3: More inconsistency generated with less crew

X4: More Inconsistency generated with batch marking

X5: More inconsistency generated by some crew.

X2: More inconsistency generated during weekends compared to weekdays


REPORT


Sheet

Too Many Orders

Too Many Customers

Lack of Crew On rest DayGov’t

Regulations

Wrong InputDo Intelligent

GuessingLost Track of

CountBatch Marking

Inefficient Crew

Some Crew Neglect to

Mark

Problem Statement

1st WHY 2nd Why 3rd Why 4th Why State Practical Theory

It is Weekend



REPORT

X6: Unavailability of forms or pen when it its needed causes

service crew to disregard marking the tally sheets.

Pen is not immediately

available

Keep in the Drawer

Common Practice


Not TrainedNo visual aid

availableNo one Made

one

X7: Absence of visual reference will diminish recall of the standard as time passes.

Forgot the procedure

No visual aid available

No one Made one

No One is Checking

No one is assigned to

check

X8: No consequence of a undesirable. behaviour promotes

undesirable behaviour to continue

Problem Statement

1st WHY 2nd Why 3rd Why 4th Why State Practical Theories


Marking is not integrated to serving Cycle.

Serving 1 cup will equate to 1 mark, X9: Separating the marking steps in the serving cycle will yield different

results


Sheet on Time

Form is Not Immediately

Available

Keep in the Folder / Nod

Defined Location

Common Practice



Sheet


REPORT

Minitab: Conduct Regression for Diff vs Cups Sales

Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by less and complete crew.

No Data: Actual Observation/interview with service crew.

Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by assigned closing crew.

Problem Statement

Verification Method

Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by weekends and weekdays.

X1: More inconsistency generated as the sales increases.




State Practical Theory


Translating to Hypothesis & Verification

Ho: Diff No Relations cups sales. Ha: Diff has Relations cups sales

Ho: Difference has no relations with less crewHa: Differences has a relations with less crew

Ho: Difference has no relations with assigned crewHa: Differences has a relations with assigned crew.

State Hypothesis Test

Ho: Weekdays has no difference with weekendsHa: Weekdays has difference with weekends

Wrong Input

Inefficient Crew



Sheet on Time

No Data: Actual Obervation: Visit the Gemba: Observe how forms are managed, asked the team of the actual situations.

No Data: Actual Observation: Visit the Gemba: Interview the Service Crew

No Data: Actual Interview: Check with Owner Manager of the current approach/ process.

1st WHY Verification Method

No Data: Actual Observation and Interview: Check the should be and

the actual process.






State Practical Theories

Serving 1 cup will equate to 1 mark, X9: separating the marking steps in the serving cycle will yield different

results

State Hypothesis test




REPORT

Problem Statement


Verification Method


Sheet


REPORT

MAN: X1: A potential cause: Relationship between Inconsistency and demand is statistically significant. MAN: X2: A potential cause: The mean of Weekdays(lower demand) is significantly different form mean Weekends.MAN: X3: Not a True Cause. No Meaningful Effect.Analysis:It is not conclusive to state both X1 and X2 are true Cause since both are dependent with X3. X3 has no meaningful effect to inconsistency. This is base on the sample data. Need to investigate more. NOT CONCLUSIVE NEED MORE DATA

METHOD True Cause, Same with X6 & X9 as delay in marking will let the crew forget.

MAN: Not a True Cause. No Meaningful Effect..

Problem Statement

Conclusion

X1: More inconsistency generated as the sales increases.






Conclusion

Wrong Input

Inefficient Crew

Minitab: Conduct Regression for Diff vs Cups Sales

Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by less and complete crew.

No Data: Actual Observation/interview with service crew.

Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by assigned closing crew.

Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by weekends and weekdays.


Verification Method


Sheet on Time

Material & Method: X6: True Cause, as delays resulted for Service crew to lost tracked of count and then inputting wrong info in the tally sheet.

Method: X7: A true cause: no reference of the correct procedure exist. New service crew were not properly trained

Method: X8: A true cause: No feedback where given since

1st WHY Conclusion

METHOD: True Cause, as delays resulted for Service crew to lost tracked of count






State Practical Theories


results




REPORT

Problem Statement

No Data: Actual Obervation: Visit the Gemba: Observe how forms are managed, asked the team the actual situations.

No Data: Actual Observation: Visit the Gemba: Interview the Service Crew

No Data: Actual Interview: Check with Owner Manager, the current approach

No Data: Actual Observation and Interview: Check the should be and

the actual process.

Conclusion


Proposed Solutions


REPORT

Elmer

Kenneth

Problem Statement

Who



Solutions and plans –Who and When

Wrong Input

Discussed with crew to try new procedure and train and implement immediately

Ask the improve to Improve the new procedure based on experience.


Sheet on Time

Elmer

Elmer / Glaiza

Elmer / Glaiza

X6: Unavailability of forms or pen when it its needed causes service crew to disregard marking the tally sheets.





results



Brainstorm with crew and solicit ideas where place tally sheet and pen to ensure it always available.

Develop Standard of Initial Procedure, trained and displayed it to the store.Develop Revised standard, re-trained and display it to the store

Modify the form to Include Tally sheet Weekly Checking and verifications of Sales.

Combine with X4. Same Solutions.

Leah

May 29 / Done

Jun 14 / Done

When/Status

May 29 / Done

June 7 / Done

Jun 17 / Done

JUN 17 / Done


So the wall was finished on the twenty- fifth day of the month Elul, in fifty- two days. And when all our enemies heard of it, all the nations around us were afraid and fell greatly in their own esteem, for they perceived that this work had been accomplished with the help of our God.

NEHEMIAH 6:15-16

9 steps on analysis

Data & Analytics