IENG 451 - Lecture 05 Process Tools: Process Capability; SIPOC and Swim Lane Diagrams 5/10/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen

IENG 451 Operational Strategies Six Sigma - Motorola Six Sigma* = 3.4 defects per million opportunities! ± 6 standard deviations – after a 1.5 sigma shift! Every Motorola employee must show bottom line results of quality project – finance, mail room, manufacturing, etc. identify problem; develop measurement; set goal; close gap Long term process – 5 years to fully implement 5/10/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen

Two Process Capability Indices Cp: Measures the potential capability of the current process - if the process were centered within the product specifications Two-sided Limits: One-sided Limit: 5/10/2018 IENG 451 Operational Strategies

Cp Relation to Process Fallout Recommended Minimum Cp Ratios: (D. C. Montgomery, 2001) Existing Process 1.25 (1-sided) 1.33 (2-sided) Existing, Safety / Critical Parameter 1.45 1.50 New Process 1.45 1.50 New, Safety / Critical Parameter 1.60 1.67 5/10/2018 IENG 451 Operational Strategies

Process Capability Indices Cpk: Measures actual capability of current process - at its’ current location with respect to product specifications Formula: Where: 5/10/2018 IENG 451 Operational Strategies

Process Capability Indices Regarding Cp and Cpk: Both assume that the process is Normally distributed Both assume that the process is in Statistical Control When they are equal to each other, the process is perfectly centered Both are pretty common reporting ratios among vendors and purchasers 5/10/2018 IENG 451 Operational Strategies

Process Capability Indices Two very different processes can have identical Cpk values, though: because spread and location interact in Cpk! USL LSL 5/10/2018 ENGM 720: Statistical Process Control

Process Capability Indices Cpm: Measures the current capability of the process - using the process target center point within the product specifications in the calculation Formula: Where target T is: 5/10/2018 ENGM 720: Statistical Process Control

IENG 451 Operational Strategies SIPOC Is an acronym for a diagram covering flow: Suppliers The external / internal entities providing the Inputs The items that flow into the scope of your Process The steps (actions) within your scope to produce Outputs The items that flow from your process scope to the Customers The external / internal entities using your outputs 5/10/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen

IENG 451 Operational Strategies SIPOC Keys for a SIPOC diagram: Identify the scope These are the process boundaries and activities Model at a high level now, lower model level with VSM Identify the KPOVs and customers Brainstorm these items If there are too many, focus on the critical few or go to a higher level Identify the KPIVs and suppliers 5/10/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen

IENG 451 Operational Strategies SIPOC Keys for a SIPOC diagram: Identify the Process Steps and CTQs These are the internal activities within the process boundaries Critical To Quality requirements must be met by the process Order of keys does not matter for a SIPOC diagram: Definitions (being specific) does matter Timing information is important (constraints) All members must understand the diagram Check definitions and scope alignment at the end 5/10/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen

IENG 451 Operational Strategies Swim Lane Charts These diagrams highlight WHO handles the flow: Identify the different people / functions that are involved in the process These are listed on the left side (vertical access) Timing is shown on horizontal access These become the swim lanes Brainstorm the steps in the Process (SIPOC): Identify them on notes / cards for As-Is, re-use for To-Be Place them in the proper swim lane, in order, connect flows Connect the notes / cards with arrows showing flow direction Communications are noted with thin lines, show informal communications with dashed, thin lines 5/10/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen

IENG 451 Operational Strategies Questions & Issues 5/10/2018 IENG 451 Operational Strategies (c) 2016 D.H. Jensen