Six Sigma Continuous Improvement Training Six Sigma Continuous Improvement Training Document and Standardize Six Sigma Simplicity

Key Learning points  Vital part of project closure  Agree on a written record - what has been done and share with all Associates  To sustain the gain - link the new procedure to formal Quality Management System or Internal Audits  Vital part of project closure  Agree on a written record - what has been done and share with all Associates  To sustain the gain - link the new procedure to formal Quality Management System or Internal Audits

Flowserve’s Continuous Improvement Process Flowserve’s Continuous Improvement Process DocumentDocument

Documentation Plan  Documenting agreed changes is an important part of building acceptance, changing processes and working through conflict  A Documentation Plan is more than a schedule for all documents.  It is helpful to define the  Scope  Schedule for creation  Ownership  Circulation  Storage/disposal

Documenting a CIP project Documents  Your final report  FMEA  Process Map  Charter  Brown Paper  Presentations/ Photographs  /memos  Flip charts  Graphs  Procedures  Training materials Documents  Your final report  FMEA  Process Map  Charter  Brown Paper  Presentations/ Photographs  /memos  Flip charts  Graphs  Procedures  Training materials What needs to be translated? Where will they be stored? Are any sensitive/ confidential? Which documents require transfer of ownership?

Documentation Plan - Exercise  Fill in the plan for the following documents for your project  Would you use the same process for all projects?  Fill in the plan for the following documents for your project  Would you use the same process for all projects?

Management Model 5S Workplace Organisation Six Sigma Tools and Process Lean Tools and Process Empowered People Quality Management System EnhancedPerformance

 What is Quality?  ISO 9001:2000  CIP Strategy & ISO 9001  Sustaining the Gain via the QMS  What is Quality?  ISO 9001:2000  CIP Strategy & ISO 9001  Sustaining the Gain via the QMS

What Do We Mean by Quality? What Do We Mean by Quality?  Quality Policy Business objectives  Quality Management Implementation of policy  Quality System Organization and procedures  Quality Control Operational techniques  Quality Assurance Satisfying requirements  Quality Manual Definition and description of policy, systems and procedures  Quality Policy Business objectives  Quality Management Implementation of policy  Quality System Organization and procedures  Quality Control Operational techniques  Quality Assurance Satisfying requirements  Quality Manual Definition and description of policy, systems and procedures ISO 9001:2000 defines quality as: “The degree to which a set of inherent characteristics fulfils requirements” Y=f (x)

ISO 9001:2000  The standard has been enhanced to increase emphasis upon:  Planning  Customer Satisfaction  Measurement of Process Effectiveness  Analysis of Process Effectiveness  Prevention  Continual Improvement  The standard has been enhanced to increase emphasis upon:  Planning  Customer Satisfaction  Measurement of Process Effectiveness  Analysis of Process Effectiveness  Prevention  Continual Improvement

What Has Changed  Organizations Certified to ISO 9001:1994 Were judged on how well they followed procedures  Organizations Certified to ISO 9001:2000 Will be judged on how well they achieve intended results The Focus is upon Capable and Predictable Processes  Organizations Certified to ISO 9001:1994 Were judged on how well they followed procedures  Organizations Certified to ISO 9001:2000 Will be judged on how well they achieve intended results The Focus is upon Capable and Predictable Processes

Flowserve’s Continuous Improvement Process Flowserve’s Continuous Improvement Process StandardizeStandardize

Model of Process-Based QMS Customer Requirements Customer Requirements Customer Satisfaction Customer Satisfaction Management Responsibility Measurement, Analysis & Improvement Product Realization Resource Management SpecificationProduct Continuous Improvement

ISO 9001:2000 The QMS is no longer a part of the organization’s management system, It is the organization’s management system. The QMS is no longer a part of the organization’s management system, It is the organization’s management system. QMS EMS Business Business QMS ISO 9000:1994 ISO 9000:2000

CIP Strategy & ISO 9001  Scope says requirements are aimed primarily at:  Enhancing customer satisfaction through the effective application of the system including processes for continual improvement...  Scope says requirements are aimed primarily at:  Enhancing customer satisfaction through the effective application of the system including processes for continual improvement... L6S, TOC, Hoshin Planning, 5S

CIP Strategy & ISO 9001 CIP Strategy & ISO 9001  Monitoring & Measurement of Processes  These methods shall demonstrate the ability of the processes to achieve planned results.  Monitoring & Measurement of Processes  These methods shall demonstrate the ability of the processes to achieve planned results. Measure: Process Mapping, SPC, Pre-Control Mechanisms, Process Capability Measure: Process Mapping, SPC, Pre-Control Mechanisms, Process Capability

CIP Strategy & ISO 9001  8.4 Analysis of data The organization shall determine, collect and analyze appropriate data to demonstrate the suitability and effectiveness of the QMS and to evaluate where continual improvements can be made. a) Customer satisfaction b) Conformity of product c) Characteristics and trends of processes and opportunities for preventative actions d) Suppliers  8.4 Analysis of data The organization shall determine, collect and analyze appropriate data to demonstrate the suitability and effectiveness of the QMS and to evaluate where continual improvements can be made. a) Customer satisfaction b) Conformity of product c) Characteristics and trends of processes and opportunities for preventative actions d) Suppliers Analyze: X-Y Matrix, MSA, ANOVA, Multi-Vari, Correlation, Regression, DOE Analyze: X-Y Matrix, MSA, ANOVA, Multi-Vari, Correlation, Regression, DOE

CIP Strategy & ISO 9001  Continual Improvement The organization shall continually improve the effectiveness of the QMS through the use of analysis of data, corrective and preventative actions and management review Preventative Action The organization shall determine action to eliminate the causes of potential non-conformities in order to prevent their occurrence  Continual Improvement The organization shall continually improve the effectiveness of the QMS through the use of analysis of data, corrective and preventative actions and management review Preventative Action The organization shall determine action to eliminate the causes of potential non-conformities in order to prevent their occurrence Improve: ANOVA, Multi-Vari, Correlation, Regression, DOE, Poka-Yoke Improve: ANOVA, Multi-Vari, Correlation, Regression, DOE, Poka-Yoke Control: Control Plans, FMEA, Mistake Proofing, Poka Yoke Control: Control Plans, FMEA, Mistake Proofing, Poka Yoke

ISO 9001 Advocates MeasureAnalyzeImproveControl The degree to which a set of inherent characteristics fulfils requirements Y = f ( x ) Define

Advantages of Using Quality System  Makes the change company policy  Makes everyone aware of the change  Provides clear definition of procedures and responsibilities  Provides control and management of the change  Audits effectiveness and discipline  Sustains the gain!  Makes the change company policy  Makes everyone aware of the change  Provides clear definition of procedures and responsibilities  Provides control and management of the change  Audits effectiveness and discipline  Sustains the gain!

Six Sigma Continuous Improvement Training Six Sigma Continuous Improvement Training Document and Standardize