Week 8 – Improve Phase Week 8 Assignment Prompt – Improve Process Map and FMEA For your project: • Showcase the new improved process with an updated process map, and an improved FMEA (with improvement recommendations, especially on the proven Xs) to minimize risks of failure. For additional details, please refer to the Short Paper/Case Study Rubric document. Also, please use my Project Charter, Measure Phase, & Analyze papers (that I have attached) – which is needed to complete this assignment. ______________________________________________________________________________ I. Instructor Notes for Week 8: Last week we went through the Analyze phase, in other words, what can we do to correct and eliminate the problem. You may have used tools like the 5 Why's or Cause and Effect diagrams as well as others to analyze you problem or issue. Now that you know what's wrong, it's time to implement the solution or as we say perform the "Improve" phase. Once you have implemented the improvement you'll need to make sure that it can work. This is where the FMEA comes into play. It gives you the opportunity to see just what could go wrong and how you're going to make sure that it doesn't. When you are looking for FMEA's look on the internet, there are a number of good options for you to use. If for some reason you can't find a good one, then let me know and I'll help you out if I can. NOTE: As a reminder, the DMADV Final Paper due in Week 10 must be at least 8-10 pages. The Final Project is to recall the DMAIC approach of a Six Sigma project. You will combine all phases into one on the real-world process that you chose as your project and explain how the DMAIC approach can be applied to improve that process. Explain each of the 5 phases (DMAIC) in as much detail as possible. However, this week is the Analyze Phase portion of your Final Paper. II. Week 8 Module Overview: The “Improve” phase of a Six Sigma project improves the process by removing the root causes of the problem. However, before implementing process changes for improvement, further statistical experiments may be designed and conducted to validate the root causes identified in the “Analyze” phase. Read the article that summarizes this important area called “Design of Experiments (DOE).” Essentially, process waste is eliminated and the “5S” methodology implemented in the “Improve” phase. Refer to Module One lecture for the eight forms of process waste and the 5S methodology. Most of the processes have faster output rate after process improvement. The following example illustrates the concepts of “takt time” and “cycle time”: Example: 60 products must be produced in 600 minutes. The “takt time” is the required output rate and is calculated as Takt Time = Available Time / Number of Products = 600 minutes / 60 products = 10 minutes per product. “Cycle time” is the average time taken by a process step to complete one product. If the “cycle time” for a process step in the above example is 20 minutes, the number of people required for that process step is calculated as Number of People = Cycle Time / Takt Time = 20 minutes / 10 minutes = 2 people. An important step in improving a process is to improve the bottleneck of the process (“A chain is only as strong as the weakest link”). The concept and methodology for doing so is called the “Theory of Constraints (TOC).” Read the article that summarizes the TOC. Any improvement project comes with potential risks, and the following tools help identify those risks: • • SWOT (Strengths-Weaknesses-Opportunities-Threats) analysis PEST (Political-Economical-Social-Technological) analysis Read the article that discusses these tools in detail. References American Society for Quality. (2011). Design of experiments. Retrieved from http://asq.org/learn-aboutquality/data-collection-analysis-tools/overview/design-of-experiments.html Pinnacle Strategies. (2011). Theory of constraints: An overview. Retrieved from http://www.pinnaclestrategies.com/Theory%20of%20Constraints.htm International Business Behavior Academy. (2011). The PEST and SWOT analysis. Retrieved from http://ibbacademy.com/pestand%20swotanalysis.htm III. THE IMPROVE PHASE – Week 8 Notes: Learning Objectives Upon completion of the course, students will be able to: • • • Discuss application of Six Sigma to a hospital process Compute Takt time and Cycle time Discuss Design of Experiments (DOE) and Theory of Constraints (DOC) Reading and Resources Textbook The Certified Six Sigma Black Belt Handbook, Chapters 1 (pp. 24), 24, 25, and 26. Website: Design for six sigma This website discusses DMADV and DMADOV. Website: Statistical tolerance This website discusses statistical tolerancing. Website: Porter’s five forces: Assessing the balance of power in a business situation This website discusses Porter’s five forces. Library Article: Improving the Hospital Discharge This article discusses how Six Sigma was applied to improve a hospital discharge process. • IV. Reference: Allen, T. T., Shih-Hsien Tseng, Swanson, K., & McClay, M. A. (2010). Improving the Hospital Discharge Process with Six Sigma Methods. Quality Engineering, 22(1), 13–20. https://doi-org.ezproxy.snhu.edu/10.1080/08982110903344812 MY PERSONAL NOTES FOR THIS ASSIGNMENT: Six Sigma Daily Glossary https://www.sixsigmadaily.com/six-sigma-terms/#tabpanel4 VERY USEFUL MANUAL ON THE FULL DMAIC PROCESS, INCLUDING THE ANALYZE PHASE (WHICH BEGINS ON PAGE 193). ALL INFORMATION BELOW, FROM THIS POINT ON DOWN, IS FROM THE FIREBRAND TRAINING MANUAL. You can click the link and scroll to page 193 for information on The Analyze Phase. LINK: Fire Brand Training Manual http://www.firebrandtraining.co.uk/pdf/learn/six-sigma/sixgreen-courseware.pdf Short Paper/Case Study Analysis Rubric Guidelines for Submission: Short papers should use double spacing, 12-point Times New Roman font, and one-inch margins. Sources should be cited according to a discipline-appropriate citation method. Page-length requirements: 1–2 pages (undergraduate courses) or 2–4 pages (graduate courses). Critical Elements Main Elements Inquiry and Analysis Integration and Application Critical Thinking Research Writing (Mechanics/Citations) Exemplary (100%) Includes all of the main elements and requirements and cites multiple examples to illustrate each element Provides in-depth analysis that demonstrates complete understanding of multiple concepts All of the course concepts are correctly applied Draws insightful conclusions that are thoroughly defended with evidence and examples Incorporates many scholarly resources effectively that reflect depth and breadth of research No errors related to organization, grammar and style, and citations Proficient (90%) Includes most of the main elements and requirements and cites many examples to illustrate each element Provides in-depth analysis that demonstrates complete understanding of some concepts Most of the course concepts are correctly applied Draws informed conclusions that are justified with evidence Needs Improvement (70%) Includes some of the main elements and requirements Not Evident (0%) Does not include any of the main elements and requirements Value 25 Provides in-depth analysis that demonstrates complete understanding of minimal concepts Some of the course concepts are correctly applied Draws logical conclusions, but does not defend with evidence Does not provide in-depth analysis 20 Does not correctly apply any of the course concepts Does not draw logical conclusions 10 Incorporates some scholarly resources effectively that reflect depth and breadth of research Minor errors related to organization, grammar and style, and citations Incorporates very few scholarly resources that reflect depth and breadth of research Does not incorporate scholarly resources that reflect depth and breadth of research 15 Some errors related to organization, grammar and style, and citations Major errors related to organization, grammar and style, and citations Earned Total 10 20 100%
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