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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