1. Tumolo’s Toolbox
7 Step Improvement Process

2. 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

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

4. 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

5. 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)

6. 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

7. 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

8. 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

9. 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)

10. 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

11. 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

12. 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.

13. 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

14. 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 or or
values

15. 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

16. 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

17. 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

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

19. 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

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

21. 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