Six Sigma (Lean)
Project_Charter
DELIVERABLE MODULE 3 – PROJECT CHARTER
Project Title:
Black Belt Project Champion Executive Sponsor MBB/Mentor
Problem Statement Business Case
Project Goals Project Scope
High Level Project Timeline Constraints & Dependencies Project Risks Additional Information
Phase Start Finish
Identify Value
Map the Value Stream
Create Flow
Establish Pull
Seek Perfection
Approval/Steering Committee Stakeholders & Advisors Project Team & SME’s
Name Organization Name Organization Name Organization
VILLANOVA UNIVERSITY
High Level Process Map
DELIVERABLE MODULE 4 – HIGH-LEVEL PROCESS MAP
Please add in extra processes and symbols as needed
SIPOC
DELIVERABLE MODULE 4 – SIPOC
Introduction and Instructions for SIPOC
SIPOC is an acronym that stands for supplier, input, process, output and customer
A SIPOC is a process mapping variant that for each process step identifies the inputs, the suppliers (internal or external) for those inputs, the outputs and the customers (internal or external) for that output
Using the template below, begin by filling in the “Process” column with the process steps identified in the high-level process map
Then, for each process step identify the inputs, the suppliers (internal or external) for the inputs, the outputs and the customers (internal or external) for the outputs
S.I.P.O.C. Template
Suppliers Inputs Process Outputs Customers
VILLANOVA UNIVERSITY
Start
Step 1
Step 2
Step 3
Step 4
End
VSM
DELIVERABLE MODULE 4 – VSM
Value Stream Map
Supplier Customer
Information Information
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Cause_Effect_Diagram
DELIVERABLE MODULE 5- CAUSE AND EFFECT DIAGRAM
Instructions:
STEP 1 : Define the problem. What is the product, process or service that has failed.
STEP 2 : Starting with ‘Materials’ or any other label, ask: is there anything about materials that
might contribute to the problem. Record it next to one of the arrows under Materials.
STEP 3 : Repeat asking “is there anything about materials that might contribute to the problem”
Problem Record each result next to an arrow.
STEP 4 : Repeat Step 2 & 3 for each successive category.
STEP 5 : Identify the candidates that are the most likely Root Cause
STEP 6 : If further “screening” is necessary, assess the likely Root Causes using the “Impact”
and “Implement” matrix, selecting items marked 1, then 2 . . . 4 as priorities.
Pareto
DELIVERABLE MODULE 5 – PARETO CHART
Categories # of Occurrences
Issue 1
Issue 2
Issue 3
Issue 4
Issue 5
5-Why’s
DELIVERABLE MODULE 5 – 5 WHY’S
5-WHY ANALYSIS SHEET
Note: Continue on separate page if 5-Whys are not enough to determine root cause.
WHY ? #1:
WHY ? #5
WHY ? #2:
WHY ? #4
WHY ? #3
TEMPORARY Date:
COUNTERMEASURES
FINAL COUNTERMEASURE Name:
– PERMANENT CORRECTIVE ACTION Date:
VERIFICATION:
No Recurrence in Three Months? TBD Date:
Single-Point Lesson? _________ Date ________
DO THE 5 WHY’S MAKE SENSE WHEN READ BACKWARD?
Waste Walk
DELIVERABLE MODULE 6 – WASTE WALK
8 Wastes/Waste Walks
Defects – Re-adjusting process parameters, reworking finished products, off spec materials Defects
Overproduction – Making anything sooner, faster or in excess of customer requirements Overproduction
Waiting – Waiting for raw materials, maintenance personnel, processes to finish, and instructions Waiting
Non Utilized Talent – Workers not involved in improvement areas; input or feedback ignored. Changes without consulting workers and employees not challenged Non Utilized Talent
Transportation – Putting products in work-in-progress areas and moving materials due to poor layout Transportation
Inventory (Excess) – Work-in-progress, rework waiting for testing, excessive raw and finished products Inventory
Motion (Excess) – Moving tools and people to defferent areas, excessing manual material movement Motion
Excessive Processing – Excessive Quality checks, Performing operations not required Excessive Processing
Waste Type Describe the waste you saw
Root Cause Analysis
Deliverable Module 6 Root Cause Analysis
Root Cause Analysis (Please state your conclusions)
Kanban
DELIVERABLE MODULE 7 – KANBAN
KANBAN CARD
Part Description/Picture if Applicable Part Number Profile
QTY. Lead Time Due Date
Supplier Location Card #
1 OF 2
KANBAN CARD
Part Description/Picture if Applicable Part Number Profile
QTY. Lead Time Due Date
Supplier Location Card #
2 OF 2
Audit_Checklist
DELIVERABLE MODULE 7 – AUDIT
Audit Checklist
Target Area: Statement of Audit Objective: Auditor: Audit Date:
Audit Technique Auditable Item, Observation, Procedure etc. Individual Auditor Rating (Circle Rating)
Observation Have all associates been trained? YES NO
Observation Is training documentation available? YES NO
Observation Is training documentation current? YES NO
Observation Are associates wearing proper safety gear? YES NO
Observation Are SOP’s available? YES NO
Observation Are SOP’s current? YES NO
Observation Is quality being measured YES NO
Observation Is sampling being conducted in random fashion YES NO
Observation Is sampling meeting it’s sample size target? YES NO
Observation Are control charts in control YES NO
Observation Are control charts current? YES NO
Observation Is the process capability index >1.0? YES NO
Number of Out of Compliance Observations
Total Observations
Audit Yield ERROR:#DIV/0!
Corrective Actions Required
Auditor Comments
VILLANOVA UNIVERSITY
