Tumolo’s Toolbox 7 Step Improvement Process

Elements of process improvement and control Every process has three (3) elements 1. The area of discovery Understanding the customer requirements and developing the process to meet these requirements 2. The method of process control Assessing performance and variation 3. The element of improvement Problem solving and quality improvement

Process Improvement Opportunity or Problem Identification 7 Step Improvement Process Process Control

Improvement or Problem the in innovation insight invention inspiration intuition instinct prayer clairvoyance Copy Imitation consultation Benchmark Other world Inner self Improvement or Problem others delegation negotiation just waiting passing-the-buck confusing finger pointing transferring real world gut feel systematic PDCA 7 Steps random trial-and-error guess accident chance luck

PDCA 7 STEP 7 QC Tools 1. Select a Theme 2. Collect Data 3. Analyze causes/opportunities 4. Plan and implement solution / improvement 5. Evaluate effects 6. Standardize 7. Reflect on process Check sheet, graph, Histogram, scatter diagram, Pareto diagram, cause-and-effect diagram, flowcharts Flowcharts run chart/control chart Flowchart PLAN DO CHECK ACT (provides repetition) (provides process) (provides tools)

7 Step improvement process 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process Focus on weakness Thoroughly explore the problem/opportunity Carefully select the theme Clearly state the theme Have weakness orientation State as a problem/gaps, not a solution State in terms of results

Selecting the theme Weakness is difference between current situation and the target. Weakness orientation focuses on eliminating weakness as basis of improvement (Closing the Gap). } } Current Customer Need Weakness Weakness Target Actual Performance Focus on facts, processes, and root causes

7 Step improvement process Define your data collection process Appropriate to process Multi-variable data Analyze the data Stratification Graphics Focus on deviation Draw a logical conclusion Based on facts Focus on vital few 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process “Primary tool used is Pareto Diagram

Frequently used data collection tools CHECKSHEET PARETO DIAGRAM CONTROL CHART GRAPH (RUN CHART) HISTOGRAM Used to systematically collect data or tabulate data. (e.g. frequency of occurrence of defect types) Excellent method to identify vital few. (2 levels minimum) (e.g. Percent of failures due to various defect types arranged in descending order of occurrence) Method to identify non-standard process variation (e.g. Solder paste height versus time) Method to identify trends in data (e.g. In circuit test yield versus time) Method to identify distribution of the data (e.g. Number or solder paste observations falling into various height ranges)

7 Step improvement process Create cause-and-effect diagram from Pareto Investigate cause thoroughly Draw logical conclusions (i.e. supported by data) 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process Ask Why?5 times

ASK 5 WHYS to get to the proper level of analysis and causes. 100% 4th why 2nd why Methods Material Pareto Diagram 5th why 3rd why 1st why A Man Machine Cause effect Diagram A B C D E F ASK 5 WHYS to get to the proper level of analysis and causes. Segment by 4 Ms Man Machine Methods Material

Verifying Root Causes Collect data on root causes Use run charts, Pareto, Graphs, scattergrams, etc. to determine strength of correlation between root cause and problem If verification fails to validate choices, return to diagram and choose new root causes to verify.

7 Step improvement process Focus on the primary root causes Focus on solution which you can implement Dont try to fix everything at once Involve those who will be affected Run a controlled experiment (Pilot) 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process

Solectron Criteria Effectiveness Feasibility Total Score A tool to help determine which solution is best. Solution 1 Solution 2 Solution 3 Solution 4 ------- Scoring values = HIGH = MEDIUM = LOW Possible score 3 or 2 or 1 values 6 3

A tool to help determine ease or difficulty in solving specific problems. Area of Problem Equipment Methods Human Behavior You You and Others Easy Easy Difficult Data Collection/ Potential solution implementation Moderately Moderately Very Difficult Difficult Difficult Very Difficult Difficult Difficult

Solution Implementation What When Where Who How How will they get it done Who is responsible for doing it Where will it be done When will it be done What will be done

7 Step improvement process Confirm improvement (Before and after comparison) Evaluate all subsequent effects Measure improvement gains over time 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process

} } Original Pareto “BEFORE Improvement New Pareto “AFTER 100% Pareto Diagram Effect on Root Cause “Fewer defects A B C D E F

7 Step improvement process Move from PDCA to SDCA cycle Revise the standard Create a process to detect future problems 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process

Standardization PDCA SDCA New Std Do Std Do Plan Act Act Check Check Control Improvement

7 Step improvement process Analyze strengths and weaknesses Determine the next problem Document the Quality improvement story Identify the critical difficulties during the process - using tools, etc. Identify the critical strengths Identify the key things the team would do differently Identify what key things the team needs to learn to improve the 7 step process. 1. Select Theme 2. Collect Data 3. Analyze Causes 4. Plan Solution and Implement 5. Evaluate 6. Standardize 7. Reflect on Process