Lesson 4 Improve the Process

Objectives You will be able to understand: The advantages of continual process improvement The key activities associated with process improvement

5. Repeat step 1 with new knowledge Improve the Process 4. Act on what was learned 1. Plan a change for improvement ACT PLAN CHECK DO 3. Analyze and interpret effects of the change 2. Carry out the change on a small scale 5. Repeat step 1 with new knowledge 6. Repeat step 2 and onward

The Batavia Incident Offshore: Less variation Batavia: More variation 10 20 30 40 50 60 70 80 90 LSL USL Target

Specifications as Goals Loss No Loss Loss (Bad) (Good) (Bad) Does not meet customer expectations Does not meet customer expectations Meets customer expectations LSL Target USL Measure of quality characteristic

Quality Loss Function Increasing Value Lost Increasing Value Lost Curve LSL Target USL Measure of quality characteristic

Continual Improvement and the Quality Loss Function Distributions A B C Value Lost Increasing Value Lost Increasing Loss A Loss B Loss C Loss B Loss A LSL Target USL Measure of quality characteristic

Activity 4.1 Plan ACT PLAN CHECK DO Plan what changes might lead to improvements Decide what data are needed Determine how, when, and by whom data will be collected ACT PLAN CHECK DO

Cause & Effect Diagram Equipment Methods Reliable elevators Better tools Assembly procedures Better training Skids & yellowgear Better training Weapons movement Reduced weapons assembly and delivery time Assembly jigs Better training Pre-assembled Components Closer storage spaces Improved watchbill Better/faster elevators Fewer weapons types Lights& ventilation Training priority Better “C” schools Grease Viscosity Straight thru elevators People Materials Environment

Activity 4.2 Do ACT PLAN CHECK DO Gather or review baseline data Make planned changes on a small scale Gather data to determine what happened after the changes

Activity 4.3 Check ACT PLAN CHECK DO Compare results of changes with what was planned Determine whether changes led to improvements CHECK DO

Activity 4.4 Act ACT PLAN CHECK DO Decide on changes Make the changes Standardize Educate & train Monitor the process Repeat the cycle ACT PLAN CHECK DO

PDCA Cycle & Process Improvement Decide on changes Make the changes Standardize Educate & train Monitor the process Repeat the cycle Plan what changes might lead to improvements Decide what data are needed Determine how, when, and by whom data will be collected ACT PLAN Compare results of changes with what was planned Determine whether changes led to improvements CHECK DO Gather or review baseline data Make planned changes on a small scale Gather data to determine what happened after the changes

Leadership Involvement Study & learn PDCA Actively participate in quality improvement Develop a TQL implementation plan Choose initial efforts that are: - Customer or mission-driven - Likely to succeed - Measurable - Designed with strategic intent

TQL Teams & Activities ESC QMB PAT A P C D 1.1 Clarify The Mission (only if required) 1.1 Clarify The Mission Clarify the Charter Task (or Charter) a PAT Train ESC Build commitment in ESC Write Implementation Plan 2.1 Describe the Process 2.2 Simplify, & 2.3 Standardize the Process PAT ID & Prioritize: 1.2 Org’s Customers 1.3 Customer Reqmts 1.4 Significant Processes 3.1 Determine Measures Assist the QMB 3.2 Construct Control Chart 2.1 Describe Processes Charter QMBs Stable ? No 3.3 Act on Special Causes Help with Flow Chart Collect data ID & remove special causes Provide ideas Assess the Organization Develop Critical Mass Create the Environment Refine Mission Improve the TQL Impl Plan Support and Extend CPI Yes 4.4 4.1 A P 3.4 Check for Capability 4.3 4.2 C D (MOM 6)

Summary of Key Activities Identify 1.1 Clarify the mission 1.2 Identify & prioritize customers 1.3 Identify & prioritize customer requirements 1.4 Identify significant processes that meet customer requirements Simplify & Standardize 2.1 Describe the process 2.2 Simplify the process 2.3 Standardize the process Stabilize 3.1 Determine process measures 3.2 Examine the process by using control charts 3.3 Act on special causes 3.4 Check for capability Improve 4.4 ACT 4.1 PLAN 4.3 CHECK 4.2 DO

Chapter Summary Process improvement is a job for everyone Process improvement must be continual Process improvement affects organizational systems You are responsible for leading process improvement

Summarize Your Responsibilities for Implementing TQL