1. Six Sigma Project Place the team photograph here Organization Name
Plant Location
Name of the Black Belt
Team Members
Date of Start
Place the team photograph here

2. Organization details
Write briefly about your Organization and products/services

3. DEFINE MEASURE & ANALYSE IMPROVE CONTROL D Define M & A Measure &

4. Phase – 1- Problem Definition
Problem Statement
Part number selected for study
Other similar part numbers having the problem
Process stages where the Problem is detected
Current average rejection for last 6 months
Maximum and Minimum rejection in last 6 months
Maximum rejection in a month -
Minimum rejection in a month -

5. Phase – 1- Problem Definition
Number of lines/presses/machines used for processing
Objective of the Project
Annual Savings in Rs. Lakhs if the defect is made zero and horizontally deployed to other part numbers
Response
Variable / Attribute
Specification (if the response is variable)
Is R&R study required
Yes / No
If R&R study is required, % R&R to tolerance

6. Phase – 1- Problem Definition
Process Mapping

7. Phase – 1- Problem Definition
Project Planning
Phase
Month W1 W2 W3 W4
Define
Measure & Analyze
Improve
Control
Phases
Planned Start date
Planned Completion date
Actual start date
Actual completion date
Status
Define
Measure & Analyze
Improve
Control

8. Phase – 1- Problem Definition
Photograph of defect part

9. Pareto (Based on last 6 months to 1 year data)
Phase – 1- Problem Definition
Pareto (Based on last 6 months to 1 year data)
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32% of the rejection is due to Blow holes.
Qty produced: nos.
Qty scrap – 540 nos.
Scrap %
Blow hole scrap – 172nos.
Blow hole scrap %
Double click on the graph to update the graph for your project

10. COPQ (Cost of Poor Quality) Calculation
Phase – 1- Problem Definition
COPQ (Cost of Poor Quality) Calculation
Number of pieces rejected last month (for the part number identified for study)
Number of pieces scrapped last month
Number of pieces reworked last month
Scrap cost/piece
Rework cost/piece
Total scrap cost (Rs. Lakhs) for last month
Total rework cost(Rs. Lakhs) for last month
Total Rejection cost (Rs. Lakhs) for last month
Extrapolated Total rejection cost (Rs. Lakhs) for one year
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Note: Rejection should include both rework and scrap

11. Phase – 1- Problem Definition
Suspected Sources of Variation for the Problem statement (SSV’s)
Transfer the above SSV’s to the next slide, write the tools you have used in the column and identify which tool has been used for which cause. Also write the name of the tool in the Legend

12. Phase – 1- Problem Definition
SSV’s
Tool#3
Tool#1
Tool#2
Tool#4
Tool#5
Tool#6
Tool#7
Tool#9
Tool#8
Legend: Tool#1 – , Tool#2 – , Tool#3 – , Tool#4 – , Tool#5 – ,Tool# , Tool#7 -
Tool# , Tool #9 -

13. DEFINE MEASURE & ANALYSE IMPROVE CONTROL D Define M & A Measure &

14. Phase – 2- Measure and Analyze
Analysis # 1
Objective:
Technique/Tool used: -

15. Phase – 2- Measure and Analyze

16. Phase – 2- Measure and Analyze

17. Phase – 2- Measure and Analyze

18. Phase – 2- Measure and Analyze
Analysis # 1
Objective:
Conclusion(s): -

19. Phase – 2- Measure and Analyze
Analysis # 2
Objective:
Technique/Tool used: -

20. Phase – 2- Measure and Analyze

21. Phase – 2- Measure and Analyze

22. Phase – 2- Measure and Analyze

23. Phase – 2- Measure and Analyze
Analysis # 2
Objective:
Conclusion(s): -

24. Phase – 2- Measure and Analyze
Analysis # 3
Objective:
Technique/Tool used: -

25. Phase – 2- Measure and Analyze

26. Phase – 2- Measure and Analyze

27. Phase – 2- Measure and Analyze

28. Phase – 2- Measure and Analyze
Analysis # 3
Objective:
Conclusion(s): -

29. Phase – 2- Measure and Analyze
Analysis # 4
Objective:
Technique/Tool used: -

30. Phase – 2- Measure and Analyze

31. Phase – 2- Measure and Analyze

32. Phase – 2- Measure and Analyze

33. Phase – 2- Measure and Analyze
Analysis # 4
Objective:
Conclusion(s): -

34. Phase – 2- Measure and Analyze
Total Analysis summary
Cause(s) identified for the problem:
Root cause(s) identified for the problem: -

35. Phase – 2 – Measure and Analyze
Funneling Summary
Funneling :
Cause(s) # 1
Tool # 1
Funneling #1
Cause(s) # 2
Funneling # 2
Tool # 2
Funneling # 3
Cause(s) # 3
Tool # 3
Funneling # 4
Cause(s) # 4
Tool # 4

36. DEFINE MEASURE & ANALYSE IMPROVE CONTROL D Define M & A Measure &

37. Validation of the Root cause(s)
Phase – 3 - Improve
Validation of the Root cause(s)
Tool used:
Data:
Conclusion:

38. Validation data for Root cause(s)
Phase – 3 - Improve
Validation data for Root cause(s)

39. Analysis of Data for Validation
Phase – 3 - Improve
Analysis of Data for Validation

40. Phase – 3 – Improve – Actions SummaryNo
Root cause(s)
Actions Planned
Planned Completion date
Resp
Actual completion date
Status

41. Phase – 3 – Improve
Photograph of actions

42. Phase – 3 – Improve
Photograph of actions

43. Phase – 3 – Improve
Photograph of actions

44. DEFINE MEASURE & ANALYSE IMPROVE CONTROL D Define M & A Measure &

45. Phase – 4 – Control Phase No Root cause Variation analysis done
Type of control method decided
Status of implementation

46. Phase – 4- Control
Analysis # 1
Objective:
Tool/technique used:

47. Data collected for Control
Phase – 4- Control
Data collected for Control

48. Phase – 4 - Control
Results
Before
After

49. Phase – 4- Control Project Summary
Number of drill down’s (funneling) done to reach the root cause(s):
Number of predominant root cause(s) identified:
Time in months for completing the project:
Tools/Techniques used:

50. Tangible Benefits derived through the project
Phase – 4 - Control
Tangible Benefits derived through the project
Overall scrap reduced from ppm to ppm
2. Defect XXX scrap reduced from --- ppm to --- ppm
Cycle time reduced from ---- seconds to seconds.
Estimated cost benefits is Rs per year.
Intangible benefits derived through the project

51. Phase – 4 - Control
Current control plan

52. Phase – 4 - Control
Proposed Control plan