METODOLOGI SIX SIGMA PERTEMUAN 12 IMPROVE PHASE OLEH: EMELIA SARI

Overview The Six Sigma team should start the Improve Phase with a clear understanding of the root causes of the problems associated with transforming the critical X’s into critical Y’s. The Improve Phase focuses on improving the processes that transform the inputs into outputs. The primary result of the Improve Phase is a redesigned process incorporating all the lessons learned through the project

Overview (2) There should be clear evidence that solutions generated and integrated into redesigned processes are capable of closing the gaps between the current process and the customer’s CTQ requirements. The new process should also demonstrate direct cost savings or increased revenue to the company. The Improve Phase is when we generate alternative process designs and then analytically choose the one that will best meet the project objectives

Process Redesign In prior phases, the CTQ input measures and the process measures have been identified and their baseline performance determined. We have matched the baseline process performance against the customer and business CTQs and identified the size of the gap that needs to be closed in order to meet the CTQs. The Improve Phase is about redesigning the processes to close the gap.

Process Redesign Principles Minimize approvals, especially multiple levels of approvals Minimize hand-offs because hand-offs create queues as well as disconnects in the workflow, leading to defects and long cycle times. Assign clear accountability for process steps. If everyone is responsible, no one is responsible Build quality control into each process step to minimize defects at all steps along the process.

Process Redesign Principles (2) Minimize or eliminate inspections or appraisal activities Balance the flow of the work to avoid bottlenecks, because bottlenecks create queues and queues create inventory and increased cycle time Minimize batch sizes of the work flowing through the process Design the process to handle the routine rather than the exceptional

Process Redesign Principles (2) Question everything. Process redesign is the time for creativity – Can the work be outsourced? – Can it be handled by another employee at the original source of the data? – Why is the work done in this department by this position? – Can process steps be combined, rearranged, or even reversed? Always consider the perspective of the customer, whether internal or external, as the new process is developed.

Generating Improvement Alternatives Brainstorming is a technique designed to produce a lot of ideas quickly. It is not meant to determine the best solution to the problem, that will come later. Affinity diagramming often follows a brainstorming session, with the goal of providing more structure to the many ideas generated. The objective of affinity diagrams is to develop meaningful ideas from a list of many unrelated ideas Force field analysis is another brainstorming-like technique that helps the team understand the driving and restraining forces associated with change

Technical Zone: Design of Experiments The advantage of using DOE is that the effects of the critical X’s interacting with each other, as well as their individual effects on the outcome, can be determined. Additionally, different levels of the X’s can be tested interactively and individually to determine the impact on the response.

Example (software: Minitab)

Cost/ Benefit Analysis To substantiate an improvement recommendation, the Six Sigma team must conduct a thorough and logical analysis of the expected costs and benefits of the change. Of course, at this point in the project, the team can only estimate total savings, based on the COPQ measurements

Implementation Plan After the improvement recommendations have been agreed upon and the cost/benefit analyses completed, it is time to develop an implementation plan, detailing what steps are necessary to implement the changes, the timeframe of implementation, who is responsible, and any assumptions made regarding implementation

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