Six Sigma at Boston Scientific Tuesday 12 September 2006 Steve Czarniak BSC Six Sigma: ASQ Meeting – 12 September 2006

Session Objectives Describe the Boston Scientific Six Sigma Model Describe the Boston Scientific Six Sigma Roadmaps Identify which Minitab graphs to use to assess measurement system performance BSC Six Sigma: ASQ Meeting – 12 September 2006

Six Sigma at BSC is... BSC Six Sigma: ASQ Meeting – 12 September 2006

Improvement Challenges Solution Known Change in Performance Operational Defect / Variation Reduction Flow Design BSC Six Sigma: ASQ Meeting – 12 September 2006

BSC Six Sigma Problem Solving Roadmap BSC Six Sigma: ASQ Meeting – 12 September 2006

BSC Six Sigma Operational Process Improvement Roadmap Process Improvement Process Define Identify Opportunity Identify y’s (Outputs) Measure y = f(x) Key x’s (Inputs) Analyze Optimize x’s Improve Control Yield Time BSC Six Sigma: ASQ Meeting – 12 September 2006

DMAIC Improvement Process Define Measure Analyze Improve Control Identify Opportunity Define Project Goal Define Process Establish Boundaries Determine Customer Requirements Define Key Y Variables Develop Measures (y’s) Evaluate Measurement System Determine Process Stability Determine Process Capability Determine the Improvement Approach Identify Potential x’s Analyze x’s Identify Key x’s Determine Stability & Capability of Key x’s Establish Relationships between y’s & x’s Establish Targets & Tolerances for Key x’s Implement Mistake Proofing Develop, Select & Verify Process Improvements Control Key x’s Validate Process Verify Long Term Capability Monitor y’s Finalize the Control System Finalize Project Charter BSC Six Sigma: ASQ Meeting – 12 September 2006

Balloon Scrap Reduction Define: Reduce balloon scrap for major scrap code by 80% Stable! Measure: Length BSC Six Sigma: ASQ Meeting – 12 September 2006

Balloon Scrap Reduction Analyze: Designed Experiment Improve / Control: Mistake Proofing – only use preferred adhesive type! 60% scrap reduction! BSC Six Sigma: ASQ Meeting – 12 September 2006

Business Process Improvement Roadmap - DMAIC Define What are you trying to accomplish? Measure How will you know the project has been successful? Analyze What elements in your process can be leveraged for improvement? Improve What is your improvement? Control What is your plan to implement and maintain the improvement? Lean and Six Sigma both use the DMAIC roadmap as a common approach for process improvement BSC Six Sigma: ASQ Meeting – 12 September 2006

Business Process Improvement BSC Six Sigma: ASQ Meeting – 12 September 2006

Price Approval Process – Reduce Time, Increase Consistency Measure Collected data on time and logistics for price approvals Analyze Developed detailed process maps, identified waste and non-value added steps, identified gaps between ideal and current state Improve Developed target state, piloted tools for standardizing price approvals and automating repetitive tasks Define Defined goal, talked to the customers and started to understand process complexity Control Developed control plan, implemented and monitored new process BSC Six Sigma: ASQ Meeting – 12 September 2006

Price Approval - Results 75% reduction in response time to customer 62% reduction in process steps 88% reduction in decision steps Standardized processes: consistency, accuracy Customer driven solution “With BPI, our main focus was on our Customer and the requirements that they had. Without their feedback and keeping them our main focus, we would have probably come up with a totally different solution for the process of requesting and receipt of approvals” – Team Leader BSC Six Sigma: ASQ Meeting – 12 September 2006

Does this product meet spec? Lower Spec Upper Spec A: yes B: no C: maybe D: not sure - phone a friend BSC Six Sigma: ASQ Meeting – 12 September 2006

Measurement System Analysis: Gage R&R

The Basic Model The total observed variation is equal to the real process variation plus the variation due to the measurement system. BSC Six Sigma: ASQ Meeting – 12 September 2006

Effect of Measurement Variation LSL USL Actual process variation - No measurement variation LSL USL Total observed variation - With measurement variation BSC Six Sigma: ASQ Meeting – 12 September 2006

Gage R & R Means of assessing the repeatability and reproducibility of a measurement system. Evaluates how much total observed variation is due to the measurement device and measurement methods LSL USL Measurement Variation vs. Actual Process Variation ? BSC Six Sigma: ASQ Meeting – 12 September 2006

Gage R&R Example: Graphical Output BSC Six Sigma: ASQ Meeting – 12 September 2006

Measurement System Terms Stability Accuracy Precision Resolution Bias Reproducibility Linearity Discrimination Repeatability Calibration BSC Six Sigma: ASQ Meeting – 12 September 2006

Gage R&R Example: Graphical Output At each table, identify ONE graphic that best describes each term. 1 3 2 4 5 6 BSC Six Sigma: ASQ Meeting – 12 September 2006

Destructive Gage R&R Reference: De Mast, Jeroen; and Trip, Albert (2005). “Gauge R&R Studies for Destructive Measurement”. Journal of Quality Technology 37 (1), pp. 40-49. BSC Six Sigma: ASQ Meeting – 12 September 2006