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 Continuation from DMAIC tools

 

Measure:

Fully understand the actual state, quantify and measure all key parameters, elements and deliverables to be improved.

1- These parameters and deliverables need to be tangible and measurable.

2- Set the inputs and outputs of the process. To what stimulus correspond what response and in what proportion, what are the processes

    involved.

 

 

 

 

 

 

3- Confirm and validate the measurements concerning repeatability and sufficiency of data.

4- Organize and tabulate the measurements in such way that will be easy to understand and manipulate for analysis.

    Example: Number of customers complaint calls, number or percent of returned products, number of defective units on a specific

    production area per unit of time or period, process time.

5- Evaluate the process capability and perform a value stream mapping of the current state listing obvious problems, bottle necks and

    road blocks. Tag these as opportunities for improvement.

 

Analyze:

1- Determine critical inputs-outputs relationships

2-Analyze the data

3- Analyze the process flow (Compare process efficiency against the best benchmarks in the industry)

4- Perform a value analysis of the process and separate value added and no value added “works” functions and activities, plus no valued

    added activities but necessary such as QC inspection, filing and recording documentation, etc

5- Find root causes, use some of the problems solution tools already explained such as: The  5 Why’s ,  The 4 M’s +1,  The 4W’s +H+W

6- Rank root causes from more to less important use FMEA and other problem solving tools

7- Make conclusions and prioritize solutions on importance weight and time urgency

 

Improve:

1- Based on the analysis performed, prioritize areas for improvement in accordance to the impacts that can be the most important for the  

   organization

2- Select the potential solutions

3- Make use of  Lean Manufacturing tools such as Six Sigma (Statistical Process Control, Value Stream Mapping, Kanban System etc.)

4- Evaluate risk potential and confirm corrective actions effectiveness

5- Implement pilot runs and make corrections if necessary

6- Deploy and  inform improvements results company wide. Train all personnel that will be involved but were not part of the main team

7- Implement improvements at full range and follow up on project transition to the final owner of the process.

8- Document improvements and changes, maintain a “Before and After Changes Results” comparative table

 

Control:     

Now that all these improvements have been implemented, now the main task will be to maintain and control what has been gained.

1- Establish  metrics control by mean of tables and charts for all key indicators with variations in time, quantity and percent against targets

2- Establish standard operating procedures

3- Establish standard  inspection and verification procedures, including audits.

4- Deploy results and project information center visible to all parties involved, score boards etc.

5- Implement corrective actions procedures and process maintenance committee

6- Recognize the effort of all participants

 

 

 

 

 

 

 

Return to Quality and Six Sigma page

Y1

X2

Process (P)

Input

Output

X2 = f(Y1) + f(P)

FMEA:

FMEA is for “Failure Mode and Effect Analysis”

This methodology was originally developed by the US Military in the late 1940’s as a method to improve the weapons and military systems to analyze and avoid costly and fatal failures. Due to it’s simplicity and affectivity it has been almost generally adopted by all companies around the world as failure preventive methodology and as a products and services improvement tool.  

 

This a very useful tool in the course of designing, improving or finding failure modes on products and services that were not evident from the original design or manufacturing process. FMEA focuses on finding the real or potential causes for failures and the effects that these failures can or could induce.

 

FMEA Types

There are many types of  FMEA depending on their specific functional deployment and here are some of them:

1- Design. Involved on design of hardware, equipment and machines

2- Process. Involved on production and assembly

3- System. Involved on universal system functions

4- Services. Involved on Services functions

5- Software. Involved on software function and applications

 

FMEA Methodology

In General the FMEA analysis method involves these steps and in this order:

1- Process, system or service under study definition

2- Potential failure mode analysis

3- Potential failures effects analysis, plus failure severity designation from 0 to 10, being 10 the most severe

4- Potential causes analysis, plus cause and effect occurrence designation from 0 to 10, being 10 the most frequent

5- Current controls, what are the best controls and methods in hand to detect and control the causes and failures, plus detection ability from 0 to    10, being 10 the least detectable failure mode

6- Determination of the RPN or Risk Priority Number = (Severity) X (Occurrence) X (Detection ability)

7- Action recommended

8- Responsibility designation

9- Action taken, conclusions and recording

10- Reassessment and periodic improvement  review

 

 

EXAMPLE OF A SIMPLE FMEA PROCESS TABLE