© 2016 Kaizen Excellence Consulting and Training Services Company
© 2016 Kaizen Excellence Consulting and Training Services Company
© 2016 Kaizen Excellence Consulting and Training Services Company
Kaizenex offers consulting and
training services to help your
organization achieve Operational
Excellence, supporting your
Continuous Improvement and
Lean and Six Sigma initiatives.
Elmer BuscadoFounder / Lean AdvisorEmail : [email protected] : +639178557722Web : www.kaizenex.com
© 2016 Kaizen Excellence Consulting and Training Services Company
Step 1: Problem Statement;
Step 2: Find the root cause/s by
asking Why 5 times.
Step 3: State the practical theory
Step 4: Develop Hypothesis Test
Statement.
Step 5: Verify Hypothesis or
Theory.
Step 6: Confirm the True Cause
and reject failed theories.
Step 7: Propose Solution
Step 8: Assign who will be responsible
Step 9: Plan date of Execution or
completion.
© 2016 Kaizen Excellence Consulting and Training Services Company
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 & 9
© 2016 Kaizen Excellence Consulting and Training Services Company
Problem Statement
1st WHY 2nd Why 3rd Why 4th Why 5th Why
Root Cause
INCONSISTENT TALLY SHEET
REPORT
No Time to Mark the Tally
Sheet
Too Many Orders
Too Many Customers
Lack of Crew On rest DayGov’t
Regulations
Wrong InputDo Intelligent
GuessingLost Track of
CountBatch Marking
Inefficient Crew
Some Crew Neglect to
Mark
It is Weekend
© 2016 Kaizen Excellence Consulting and Training Services Company
Problem Statement
1st WHY 2nd Why 3rd Why 4th Why 5th Why
Root Cause
INCONSISTENT TALLY SHEET
REPORT
Pen is not immediately
available
Keep in the Drawer
Common Practice
Not Following Procedure
Not TrainedNo visual aid
availableNo one Made
one
Forgot the procedure
No visual aid available
No one Made one
No One is Checking
No one is assigned to
check
Actual Process are inadequate
Marking is not integrated to serving Cycle.
Unable to Mark Tally
Sheet on Time
Form is Not Immediately
Available
Keep in the Folder / Nod
Defined Location
Common Practice
© 2016 Kaizen Excellence Consulting and Training Services Company
X1: More inconsistency generated as the demand increases.
X3: More inconsistency generated with less crew
X4: More Inconsistency generated with batch marking
X5: More inconsistency generated by some crew.
X2: More inconsistency generated during weekends compared to weekdays
INCONSISTENT TALLY SHEET
REPORT
No Time to Mark the Tally
Sheet
Too Many Orders
Too Many Customers
Lack of Crew On rest DayGov’t
Regulations
Wrong InputDo Intelligent
GuessingLost Track of
CountBatch Marking
Inefficient Crew
Some Crew Neglect to
Mark
Problem Statement
1st WHY 2nd Why 3rd Why 4th Why State Practical Theory
It is Weekend
© 2016 Kaizen Excellence Consulting and Training Services Company
INCONSISTENT TALLY SHEET
REPORT
X6: Unavailability of forms or pen when it its needed causes
service crew to disregard marking the tally sheets.
Pen is not immediately
available
Keep in the Drawer
Common Practice
Not Following Procedure
Not TrainedNo visual aid
availableNo one Made
one
X7: Absence of visual reference will diminish recall of the standard as time passes.
Forgot the procedure
No visual aid available
No one Made one
No One is Checking
No one is assigned to
check
X8: No consequence of a undesirable. behaviour promotes
undesirable behaviour to continue
Problem Statement
1st WHY 2nd Why 3rd Why 4th Why State Practical Theories
Actual Process are inadequate
Marking is not integrated to serving Cycle.
Serving 1 cup will equate to 1 mark, X9: Separating the marking steps in the serving cycle will yield different
results
Unable to Mark Tally
Sheet on Time
Form is Not Immediately
Available
Keep in the Folder / Nod
Defined Location
Common Practice
© 2016 Kaizen Excellence Consulting and Training Services Company
No Time to Mark the Tally
Sheet
INCONSISTENT TALLY SHEET
REPORT
Minitab: Conduct Regression for Diff vs Cups Sales
Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by less and complete crew.
No Data: Actual Observation/interview with service crew.
Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by assigned closing crew.
Problem Statement
Verification Method
Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by weekends and weekdays.
X1: More inconsistency generated as the sales increases.
X3: More inconsistency generated with less crew
X4: More Inconsistency generated with batch marking
X5: More inconsistency generated by some crew.
State Practical Theory
X2: More inconsistency generated during weekends compared to weekdays
Translating to Hypothesis & Verification
Ho: Diff No Relations cups sales. Ha: Diff has Relations cups sales
Ho: Difference has no relations with less crewHa: Differences has a relations with less crew
Ho: Difference has no relations with assigned crewHa: Differences has a relations with assigned crew.
State Hypothesis Test
Ho: Weekdays has no difference with weekendsHa: Weekdays has difference with weekends
Wrong Input
Inefficient Crew
© 2016 Kaizen Excellence Consulting and Training Services Company
Unable to Mark Tally
Sheet on Time
No Data: Actual Obervation: Visit the Gemba: Observe how forms are managed, asked the team of the actual situations.
No Data: Actual Observation: Visit the Gemba: Interview the Service Crew
No Data: Actual Interview: Check with Owner Manager of the current approach/ process.
1st WHY Verification Method
No Data: Actual Observation and Interview: Check the should be and
the actual process.
X6: Unavailability of forms or pen when it its needed causes
service crew to disregard marking the tally sheets.
X7: Absence of visual reference will diminish recall of the standard as time passes.
X8: No consequence of a undesirable. behaviour promotes
undesirable behaviour to continue
State Practical Theories
Serving 1 cup will equate to 1 mark, X9: separating the marking steps in the serving cycle will yield different
results
State Hypothesis test
Not Following Procedure
Actual Process are inadequate
INCONSISTENT TALLY SHEET
REPORT
Problem Statement
© 2016 Kaizen Excellence Consulting and Training Services Company
Verification Method
No Time to Mark the Tally
Sheet
INCONSISTENT TALLY SHEET
REPORT
MAN: X1: A potential cause: Relationship between Inconsistency and demand is statistically significant. MAN: X2: A potential cause: The mean of Weekdays(lower demand) is significantly different form mean Weekends.MAN: X3: Not a True Cause. No Meaningful Effect.Analysis:It is not conclusive to state both X1 and X2 are true Cause since both are dependent with X3. X3 has no meaningful effect to inconsistency. This is base on the sample data. Need to investigate more. NOT CONCLUSIVE NEED MORE DATA
METHOD True Cause, Same with X6 & X9 as delay in marking will let the crew forget.
MAN: Not a True Cause. No Meaningful Effect..
Problem Statement
Conclusion
X1: More inconsistency generated as the sales increases.
X3: More inconsistency generated with less crew
X4: More Inconsistency generated with batch marking
X5: More inconsistency generated by some crew.
State Practical Theory
X2: More inconsistency generated during weekends compared to weekdays
Conclusion
Wrong Input
Inefficient Crew
Minitab: Conduct Regression for Diff vs Cups Sales
Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by less and complete crew.
No Data: Actual Observation/interview with service crew.
Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by assigned closing crew.
Minitab: Conduct effect Screen with X6, X7, & X9, If result is meaningful for X6 then Perform 2 sample test for diff by weekends and weekdays.
© 2016 Kaizen Excellence Consulting and Training Services Company
Verification Method
Unable to Mark Tally
Sheet on Time
Material & Method: X6: True Cause, as delays resulted for Service crew to lost tracked of count and then inputting wrong info in the tally sheet.
Method: X7: A true cause: no reference of the correct procedure exist. New service crew were not properly trained
Method: X8: A true cause: No feedback where given since
1st WHY Conclusion
METHOD: True Cause, as delays resulted for Service crew to lost tracked of count
X6: Unavailability of forms or pen when it its needed causes
service crew to disregard marking the tally sheets.
X7: Absence of visual reference will diminish recall of the standard as time passes.
X8: No consequence of a undesirable. behaviour promotes
undesirable behaviour to continue
State Practical Theories
Serving 1 cup will equate to 1 mark, X9: separating the marking steps in the serving cycle will yield different
results
Not Following Procedure
Actual Process are inadequate
INCONSISTENT TALLY SHEET
REPORT
Problem Statement
No Data: Actual Obervation: Visit the Gemba: Observe how forms are managed, asked the team the actual situations.
No Data: Actual Observation: Visit the Gemba: Interview the Service Crew
No Data: Actual Interview: Check with Owner Manager, the current approach
No Data: Actual Observation and Interview: Check the should be and
the actual process.
Conclusion
© 2016 Kaizen Excellence Consulting and Training Services Company
Proposed Solutions
INCONSISTENT TALLY SHEET
REPORT
Elmer
Kenneth
Problem Statement
Who
X4: More Inconsistency generated with batch marking
State Practical Theory
Solutions and plans –Who and When
Wrong Input
Discussed with crew to try new procedure and train and implement immediately
Ask the improve to Improve the new procedure based on experience.
Unable to Mark Tally
Sheet on Time
Elmer
Elmer / Glaiza
Elmer / Glaiza
X6: Unavailability of forms or pen when it its needed causes service crew to disregard marking the tally sheets.
X7: Absence of visual reference will diminish recall of the standard as time passes.
X8: No consequence of a undesirable. behaviour promotes
undesirable behaviour to continue
Serving 1 cup will equate to 1 mark, X9: separating the marking steps in the serving cycle will yield different
results
Not Following Procedure
Actual Process are inadequate
Brainstorm with crew and solicit ideas where place tally sheet and pen to ensure it always available.
Develop Standard of Initial Procedure, trained and displayed it to the store.Develop Revised standard, re-trained and display it to the store
Modify the form to Include Tally sheet Weekly Checking and verifications of Sales.
Combine with X4. Same Solutions.
Leah
May 29 / Done
Jun 14 / Done
When/Status
May 29 / Done
June 7 / Done
Jun 17 / Done
JUN 17 / Done
© 2016 Kaizen Excellence Consulting and Training Services Company
So the wall was finished on the twenty- fifth day of the month Elul, in fifty- two days. And when all our enemies heard of it, all the nations around us were afraid and fell greatly in their own esteem, for they perceived that this work had been accomplished with the help of our God.
NEHEMIAH 6:15-16