Quality Progress - January 2016 - (Page 46)

BACK TO BASICS Best of APRIL 2012 BY SCOTT FORCE Creative Combination 3 tools to jump-start a lean Six Sigma project SINCE 2002, I have been facilitating lean cle in Figure 1, or the recurring systemic Six Sigma projects and coaching other causes showing up in multiple locations, the left side of the matrix and the outputs belts through their projects. Combining shown in Online Figure 1. But what do we from the SIPOC diagram along the top tools is a technique I use with teams when do in the case of Online Figure 2? allows teams to rate the relationship each potential root cause analysis through a By combining the completed fishbone Putting the causes from a fishbone on cause has with each output, helping to fishbone diagram does not show any obvi- diagram with two other tools from our rank and prioritize potential causes the ous direction. Six Sigma tool kit, we can take a strategic team should investigate first. approach to proceed. Fishbone diagram A completed cause and effect matrix is shown in Online Table 2. The top portion From using the fishbone diagram, most SIPOC diagram shows the outputs from a SIPOC diagram quality professionals know there are usu- Using a suppliers, inputs, process, outputs for making a hamburger. The left side ally three outcomes: and customers (SIPOC) diagram, map the shows the results of a fishbone diagram. 1. One of the bones in the diagram is full high-level flow for the process to which In this example, only main causes are of potential causes, leading a team to the fishbone diagram is tied. The key shown, but it is recommended that a team focus on a particular area (Figure 1). items we will use from this tool are the list use the five whys and display the lowest- of outputs (Online Figure 3). level causes on the diagram. indicating a systemic cause that, if Cause and effect matrix the hamburger has the greatest relation- eliminated, will address several areas The cause and effect matrix shown in ship with our SIPOC outputs, indicating of concern (see Online Figure 1, found Online Table 1 is what ties together the the team should focus on that cause on this article's webpage at www. outputs of the fishbone diagram with the first. qualityprogress.com). outputs from the SIPOC diagram. Part of 2. The same potential root causes appear In this generic example, overcooking in several bones of the diagram, the quality function deployment house of Tool teamwork the diagram, and all bones show sev- quality, the cause and effect matrix is the While the SIPOC diagram focuses on de- eral potential causes (Online Figure 2). center section of the house and is also sired outcomes and the fishbone diagram In the first two cases, the team has known as a relationship matrix. focuses on the undesired causes of a 3. No common cause is seen throughout some direction by strategically focusing on the particular bone, shown by the cir- The details of completing a cause and effect matrix are beyond the scope of this column. But the basic Several potential causes on one bone / FIGURE 1 Man Machine problem, creatively combining these tools provides the team with more options on how to proceed with the project. process uses a cross- As a lean Six Sigma practitioner, you multiplication method should begin to see how many of the tools in which each row and and techniques naturally work together column intersection is to provide a more focused approach on scored by the team for the process improvement. QP degree of relationship and is multiplied with a rating Effect of importance provided by the customer. Each of these multiplications is added across the horizon- Method Material tal row, providing the final score at the far right. 46 QP * www.qualityprogress.com SCOTT FORCE is a Six Sigma Master Black Belt trained by Sigma Breakthrough Technologies Inc. with more than 20 years of quality improvement experience in the healthcare, automotive and power equipment industries. He earned a bachelor's degree in manufacturing engineering from Miami University in Oxford, OH. A senior member of ASQ, Force is an ASQ-certified quality technician, engineer and Six Sigma Black Belt. http://www.qualityprogress.com http://www.qualityprogress.com

Table of Contents for the Digital Edition of Quality Progress - January 2016

According to Plan
Solid Proof
Use Your Head
Stakeholder Management 101
Customer Delight
All About Data
Eight Simple Steps
Minimizing Chaos
Take Note
Pyramid Scheme
Assessing Failure
Which Six Sigma Metric Should I Use?
Turning ‘Who’ Into ‘How’
In the Beginning
Outputs and Outcomes
That’s So Random—Or Is It?
Understanding Variation
Improving a System
Putting It All on the Table
Know the Drill
It’s Fun To Work With an F-M-E-A
Solve Problems With Open Communication
Tell Me About It
Separate the Vital Few From the Trivial Many
To DMAIC or Not to DMAIC?
Breaking It Down
Smart Charting
1 + 1 = Zero Defects
QFD Explained
Curve Your Enthusiasm
Make a Choice
What Is a Fault Tree Analysis?
Successful Relationship Diagrams
The Benefits of PDCA
Creative Combination
Return on Investment
The Art of Root Cause Analysis
Why Ask Why?
Get to the Root of It
Checks and Balances
Calculated Risk
Sufficient Evidence
Sample Wise
Clearing SPC Hurdles
Supplier Selection and Maintenance
Team Advantage
Building a Quality Team
Plan Experiments to Prevent Problems
Substantiation Test
Training Day

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