2. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 2 Lesson 4 Improve the Process

3. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 3 Objectives You will be able to understand: The advantages of continual process improvement The key activities associated with process improvement

4. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 4 ACTPLAN DOCHECK Improve the Process 1. Plan a change for improvement 2. Carry out the change on a small scale 3. Analyze and interpret effects of the change 4. Act on what was learned 5. Repeat step 1 with new knowledge 6. Repeat step 2 and onward

5. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 5 The Batavia Incident Target LSLUSL 6070809010203040 Offshore: Less variation Batavia: More variation 50

6. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 6 Specifications as Goals Target Loss (Bad) No Loss (Good) Loss (Bad) Does not meet customer expectations Meets customer expectations LSL USL Measure of quality characteristic Does not meet customer expectations

7. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 7 Quality Loss Function Target LSL USL Measure of quality characteristic Loss Function Curve Increasing Value Lost Increasing Value Lost

8. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 8 Continual Improvement and the Quality Loss Function Target LSL USL Measure of quality characteristic BA Distributions AB C Loss ABC Value Lost Increasing Value Lost Increasing

9. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 9 Activity 4.1 Plan ACTPLAN DOCHECK Plan what changes might lead to improvements Decide what data are needed Determine how, when, and by whom data will be collected

10. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 10 Cause & Effect Diagram Reduced weapons assembly and delivery time EnvironmentMaterials People EquipmentMethods Pre-assembled Components Fewer weapons types Grease Viscosity Better tools Skids & yellowgear Assembly jigs Reliable elevators Better training Improved watchbill Better “C” schools Assembly procedures Weapons movement Closer storage spaces Better/faster elevators Lights& ventilation Straight thru elevators Better training Better training Training priority

11. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 11 Activity 4.2 Do ACTPLAN DOCHECK Gather or review baseline data Make planned changes on a small scale Gather data to determine what happened after the changes

12. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 12 Activity 4.3 Check Compare results of changes with what was planned Determine whether changes led to improvements ACTPLAN DOCHECK

13. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 13 Activity 4.4 Act ACTPLAN DOCHECK Decide on changes Make the changes Standardize Educate & train Monitor the process Repeat the cycle

14. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 14 PDCA Cycle & Process Improvement ACTPLAN DOCHECK Plan what changes might lead to improvements Decide what data are needed Determine how, when, and by whom data will be collected Gather or review baseline data Make planned changes on a small scale Gather data to determine what happened after the changes Compare results of changes with what was planned Determine whether changes led to improvements Decide on changes Make the changes Standardize Educate & train Monitor the process Repeat the cycle

15. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 15 Leadership Involvement Study & learn PDCA Actively participate in quality improvement Develop a TQL implementation plan Choose initial efforts that are: - Customer or mission-driven - Likely to succeed - Measurable - Designed with strategic intent

16. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 16 1.1 Clarify The Mission Train ESC Build commitment in ESC Write Implementation Plan ESCQMB Clarify the Charter Stable ? 4.4 4.1 4.24.3 PAT Assist the QMB TQL Teams & Activities ID & Prioritize: 1.2 Org’s Customers 1.3 Customer Reqmts 1.4 Significant Processes 2.1 Describe Processes Charter QMBs Assess the Organization Develop Critical Mass Create the Environment Refine Mission Improve the TQL Impl Plan Support and Extend CPI 2.1 Describe the Process 2.2 Simplify, & 2.3 Standardize the Process 3.1 Determine Measures 3.2 Construct Control Chart 3.4 Check for Capability 3.3 Act on Special Causes (only if required) Task (or Charter) a PAT Help with Flow Chart Collect data ID & remove special causes Provide ideas No Yes (MOM 6) PA D C

17. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 17 Summary of Key Activities Identify Simplify & Standardize Stabilize Improve 1.1 Clarify the mission 1.2 Identify & prioritize customers 1.3 Identify & prioritize customer requirements 1.4 Identify significant processes that meet customer requirements 2.1 Describe the process 2.2 Simplify the process 2.3 Standardize the process 3.1 Determine process measures 3.2 Examine the process by using control charts 3.3 Act on special causes 3.4 Check for capability 4.4 ACT 4.1 PLAN 4.2 DO 4.3 CHECK

18. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 18 Chapter Summary Process improvement is a job for everyone Process improvement must be continual Process improvement affects organizational systems You are responsible for leading process improvement

19. SENIOR LEADER'S SEMINAR CHAPTER 5 LESSON 4. 19 Summarize Your Responsibilities for Implementing TQL