Mahindra Black Belt Project Template - New

8/20/2019 Mahindra Black Belt Project Template - New

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Build QM competence | Application orientation | Spread QM | Build team culture | Quality a way of life

Lean Sigma Project

Dated: ____ / ____ / ________



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Define


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Buine !pportunity

y1 y2 y3 y4

x1.1 x1.2 x1.3

x1.1 x1.2 x1.3

x1.1 x1.2 x1.3

x1.1 x1.2 x1.3

"op Le#el $ %Big $& 'mpact een at

!perational Buine Le#el


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(ritical to Quality and (ritical to Proce()art

Critical to

Quality

Critical

customerrequirement

Customer

issues

Voice of

customer

Voice ofbusiness

Businessissues

Criticalbusiness

requirement

Critical forprocesses

*emar+1. Voice of customer and voice of business to be prioritized to tose !ic are related to pro"ect ob"ective2. #se V$B or V$C or bot dependin% on te pro"ect ob"ectives


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"eam ()arter

Project "itle

Buine (ae !pportunity Statement

&ain

'mpact of pain in (s. )or soft*

+i%ma ,evel

,oal tatement Project cope

Metric Currentlevel

Goal /Target

Target date &rocess under improvement-

+tarts !it

nds !it

Project plan "eam Selection

Phase Start End Remarks

/efine Campion-

0easure B BB

nalyze 0ember

'mprove 0ember

Control 0ember


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Miletone Sc)edule

P)ae Acti#ityno

Acti#ity Decription Plannedtart

Actualtart

Plannedcompletion

Actual(ompletion

Sign off -y()ampion

Sign off-y "QM'

/ /1 Business impact/2 eam Carter

/3 V$C5CC(5CQ6 V$B5CB(7C&

/4 +'&$C

/8 /C

/9 :/C /etailed &rocess map

/; &rocess Quic=


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Miletone Sc)edule %(ontd.&

P)ae Acti#ityno

Acti#ity Decription Plannedtart

Actualtart

Plannedcompletion

Actual(ompletion

Sign off -y()ampion

Sign off-y "QM'

1 #se &areto and stratify ys 2 (edo 'si=a!a dia%ram

3 Carry out &rocess :0

4 xtract Quic= !ins

8 mploy Comparative metods to analyse data

9 Base line performance of xs and setimprovement %oal for eac x

; :ix 'mprovement %oal for eac selected x

'1 carryout affinity dia%ram

'2 /o +olution mappin% six tin=in% ats

'3 +elect solutions

'4 &ilot te solution

'8 Validate te improvement

C1 'mplementation &lan

C2 (evie! and release :/&

C3 (edo :05'ntroduce 0ista=e proofin%C4 'nstall Control Carts

C8 0onitor xs

C9 1.'nte%rate !it '+$ system

C; &repare for pro"ect closure and reco%nition


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S'P!( D'A,*AM

Supplier 'nput Proce !utput (utomer

0a"or step 1

0a"or step 2

0a"or step 3

0a"or step 4

Proce ame+tartin% point-

nd point-


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&ro"ect title

"op Down ()art for P*!(0SS

+tartin% point-nd point-


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1unctional Deployment ()art

Step 1unction / *eponi-ility

1unction23 1unction24 1unction25 1unction26 1unction27 1unction28 1unction29


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C E

.

C E C E

.

C E C E C E

E E E E E E

C E

E

(urrent alue Stream Map


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Proce !-er#ation


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Proce Data (ollection 1orm

; i Pl i


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Phase 1

Evaluation

Phase 2

Planning

&

Preparation

Phase 3

Event

Phase 4

Follow-up

---Weeks -- Week On going

;ai


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Qualitati#e Analyi

Sr= o= Acti#ity (utomer

alue added

!perational

alue added

on2#alue

Added

&ro"ect itle-&ilot &ro"ect-

Q alitati e Anal i


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&ro"ect itle-&ilot &ro"ect-

+r.

Fo.

+ource Concerns

'ssues

&otential

Quic= !inopportunity)solution*

asy to

implement

:ast to

implement

Ceap to

implement


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Quic+ >in 'mplementation Plan

S= o= Quic+ win Acti#itie *eponi-ilitie

Peron

Start

Date

"arget

date ofcompletion

Actual

date ofcompletion

Standardi


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1uture alue Stream Map


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C E

.

C E C E

.

C E C E C E

E E E E E E

C E

E

1uture alue Stream Map

Quic+ >in *eult


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Quic+ >in *eult


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Meaure

')i+awa Diagram %(aue and 0ffect Diagram&


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')i+awa Diagram %(aue and 0ffect Diagram&

Major (ategorie of caue of Pro-lem Statement

Pro-lemStatement

Mac)ine%,eneric (ategory&

Material%,eneric (ategory&

0n#ironment%,eneric (ategory&

(aue

Su-2(aue

People%,eneric (ategory&

Met)od%,eneric (ategory&

Cause5ffect 0atrix


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Cause5ffect 0atrix

!utput ?3 !utput ?4 !utput ?5 !utput ?6 !utput 'ndicator

'nput &rocessindicators

Correlation of input to output otal

Scale: @one 3Low 5Moderate CStrong


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Sl= o= Performance 'ndicator %$& !perational definition

1

2

3

4

Sl= o= Proce / input indicator %& !perational definition

@1

@2

@3

@4

..

..

(emar=s-


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Data Meaurement Plan

(emar=s-$ter data refers to additional information from stratification perspective.

Performancemeaure %$&

!perationaldefinition

Data ourceand location

Sample

i)o will

collect t)e data

>)en willdata -e

collected

Eow willdata -e

collected

!t)er data t)at)ould -e collected

at t)e ame time

Proce /'nput %&

!perationaldefinition

Data ourceand location

Sample

i)o will

collect t)e data

>)en willdata -e

collected

Eow willdata -e

collected

!t)er data t)at)ould -e collected

at t)e ame time


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(arryout MSA

a reFuired

Data collection 1ormat %Modify a per


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% y preFuirement&

Data Summari


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% &

1ir continuou %$&

!utput indicator A#erage Standard de#iation (p (p+ Sigma Le#el1

2

3

Ge Eitogram BoH Plot 'ndi#idual c)art a appropriate %pate output of Minita-/ Sigma L&

1ir dicrete %$&

!utput indicator o= of unit o= of opportunitie per unit o= of defect DPM! Sigma Le#el

1

2

3

Summary Data %ue decripti#e tatitic in Minita- / Sigma L&

Baeline definition

>or+)eet for (alculating


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Sigma Performance continuou data

1. La-el t)e normal cur#e wit) t)e following:

2. Determine Area 3 :

:ind H1

,oo= up H1 in Formal able

rea 1 E 1 I ,oo= #p

3. +=ip tis step if tere is no ,+,Determine Area 4 -

:ind H2

Form /ist )H1* E Formal able ,oo= #p for H1

rea 1 E 1 I Form /ist )H1* E 1 I ) *

E .982319

E .;42?1

E .28;??

E

Calculatin% +i%ma &erformancenter

/elete if no #+,

/elete if no ,+,

@bar

+

#+,

,+,

9.;

.1833

9.>

.98 +i%ma

( ) ( )( )−

=

−

=

s

xUSL Z

1

( ) ( )( )

−

=

−

=

s

xUSL Z

2

>or+)eet for (alculating


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:ind H2


rea 2 E ,oo= #p

4. Determine "otal Area

8. $ield 3 I "otal Area

9. Proce Sigma (ome from"a-le Loo+up of yield


rea 2

E F

E F

E .28;??

E .;42?1E;4.2?1J

E .98

E F

otal rea E rea 1 K rea 2 E ) * K ) *

ield E 1 I otal rea E 1 I ) *E x 1J

+i%ma+ E ,oo=up value in +i%ma able

( ) ( )( )−

=

−

=

s

X LSL Z

2

>or+)eet for (alculating Sigma Performance


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1. Fumber of units processed

2. otal number of defects made)'nclude /efects made and ,ater :ixed*

3. Fumber of defect opportunities per unit

4. +olve for defects per million opportunities

8. ,oo= #p process si%ma in abrid%ed si%maconversion table

0nter

FE 8

/E 8;

$E 33>

+i%maE 3.2;

Proce Baeline for Lean Project


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&rocess steps-

a=t (ate or a=t ime-


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Analy


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&rocess product :0 /ate )$ri%inal*

:0 eam )(evised*

Blac= belt reen belt &a%e- $f

&rocess ctions (esults

&rocesssteps requirem

ents

&otentialfailure

mode

&otentialeffects of

failure

+everity&otentialcause)s*

of failure

$ccurrence

Currentcontrols

/etection

(is=priority

number

(ecommended

action

(esponsibility andtar%et

completion date

ctionta=en

+everity$ccurrence

/etection

(is=priority

number

ext ext ext Fumber ext Fumber ext Fumber calculation

ext ext ext Fumber Fumber Fumber Calculation

Pareto Analyi %'f $ i dicrete data&


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Add Pareto Diagram here

(oncluion:

0ulti5vari nalysis )'f is Continuous data*


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dd ree /ia%ram and 0ulti5vari Cart ere

(oncluion:

alidation of


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Validate eac of te prioritized @ usin% tools li=e Comparative

0etods and Correlation. $ptimize usin% /$ as needed.

(oncluion:

alidation of


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:or lean pro"ects6 identify ime rap Constraints. #se ime

Value 0ap or a=t time carts.

(oncluion:

Summary of alidated


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S= o= identified a important from 1M0A / (0 MatriH alidated %$/& "ool Ged *emar+ %attac) Minita- /Sigma L output&

1

2

3

4

8

9

;

>

?

1

11

12


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'mpro#e

Lit Poi-le Solution %Ge tool li+e Braintorming lateral t)in+ing iH


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%Ge tool li+e Braintorming lateral t)in+ing iHt)in+ing )at etc=&

S= o= #alidated Poi-le olution

1 1.1

1.2

1.3

1.4

1.8

2 2.1

2.2

2.3

2.4

2.8

3 3.1

3.2

1uture alue Stream Map %SM&


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C E

.

C E C E

.

C E C E C E

E E E E E E

C E

E

Project / Action out of 1uture SM


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1or Lean Project Lit Poi-le Solution%Ge tool li+e 7S Set up reduction >or+ control ytem=&

'f you ue 7S

o= of red tag puto= of red tag addreed

State Before and After %)ow p)otograp)/ picture&

Standard met)od/ c)ec+ lit of cleaning etc=


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'f you ue Set up reduction ue t)e flow c)art=

(laify t)e tep a Kin erie %internal& or Kparallel %eHternal&

Define )ow eHternal were con#erted to internal

And )ow internal were made more efficient

S)ow tate of et up time -efore and after=



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'f you ue >or+ (ontrol Sytem

1ollow tep gi#en on page 96 %ection 6=6&


Solution election MatriH %(aue23&


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+i%ma impact ime impact Cost benefit impact $ter impacts valuation criteria

1 > 9 'mportance

5+olution5 Correlation of solution to criteria 5otal 5 %ent ? ? 3 1>

Solution election MatriH %(aue24&

+i%ma impact ime impact Cost benefit impact $ter impacts valuation criteria

1 > 9 'mportance


Solution election MatriH %(aue25&+i%ma impact ime impact Cost benefit impact $ter impacts valuation criteria

1 > 9 'mportance


Pilot implementation planning


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"a+ Acti#itie *eponi-le peron Start Date Due Date Statu andAction

+cope of pilot -

ime line-

*eult %attac) )eet from Minita- or Sigma L&

!utput indicator A#erage Standard de#iation (p (p+ Sigma Le#el DPM! Action Plan

1

2

3

1ailure Mode J 0ffect Analyi to confirmany concern in olution -eing propoed=


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y g p p

&rocess product :0 /ate )$ri%inal*

:0 eam )(evised*

Blac= belt reen belt &a%e- $f

&rocess ctions (esults

&rocesssteps requirements

&otentialfailure

mode

&otentialeffects offailure

+everity&otentialcause)s*of failure

$ccurrence

Currentcontrols

/etection

(is=prioritynumber

(ecommendedaction

(esponsibility andtar%etcompletion date

ctionta=en

+everity$ccurrence

/etection

(is=prioritynumber

ext ext ext Fumber ext Fumber ext Fumber calculation

ext ext ext Fumber Fumber Fumber Calculation


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(ontrol

1ull Scale 'mplementation Plan

"a+ Acti#itie *eponi-le peron Start Date Due Date Statu and


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"a+ Acti#itie *eponi-le peron Start Date Due Date Statu andAction

'mplementationstrate%y

+equential &ased &arallel :lat )/etails to be added*

ime line-

*eult %attac) )eet from Minita- or Sigma L&

!utput indicator A#erage Standard de#iation (p (p+ Sigma Le#el DPM! Action Plan

1

2

3

>or+)eet for (alculatingSigma Performance continuou data


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1. La-el t)e normal cur#e wit) t)e following:

2. Determine Area 3 :

:ind H1


rea 1 E 1 I ,oo= #p

3. +=ip tis step if tere is no ,+,Determine Area 4 -

:ind H2


rea 1 E 1 I Form /ist )H1* E 1 I ) *

E .982319

E .;42?1

E .28;??

E

Calculatin% +i%ma &erformancenter

/elete if no #+,

/elete if no ,+,

@bar

+

#+,

,+,

9.;

.1833

9.>

.98 +i%ma

( ) ( )( )−

=

−

=

s

xUSL Z

1

( ) ( )( )

−

=

−

=

s

xUSL Z 2

>or+)eet for (alculatingSigma Performance continuou data


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S g a e o a ce co t uou data

:ind H2


rea 2 E ,oo= #p

4. Determine "otal Area

8. $ield 3 I "otal Area

9. Proce Sigma (ome from"a-le Loo+up of yield


rea 2

E F

E F

E .28;??

E .;42?1E;4.2?1J

E .98

E F

otal rea E rea 1 K rea 2 E ) * K ) *

ield E 1 I otal rea E 1 I ) *E x 1J

+i%ma+ E ,oo=up value in +i%ma able

( ) ( )( )−

=

−

=

s

X LSL Z 2

>or+)eet for (alculating SigmaPerformance


54/66


Performance

1. Fumber of units processed

2. otal number of defects made)'nclude /efects made and ,ater :ixed*

3. Fumber of defect opportunities per unit

4. +olve for defects per million opportunities

8. ,oo= #p process si%ma in abrid%ed si%maconversion table

0nter

FE 8

/E 8;

$E 3

3>

+i%maE 3.2;

Proce Performance for Lean Project


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&rocess steps- a=t (ate or a=t ime-


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Step 1unction / *eponi-ility

1unction23 1unction24 1unction25 1unction26 1unction27 1unction28 1unction29


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C E

.

C E C E

.

C E C E C E

E E E E E E

C E

E

1uture alue Stream Map%at t)e end of t)i Project&

Proce (ontrol Sytem


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Proce (ontrol Sytem

'nput Proce

outcome indicator

(ontrol limit ()ec+ing item 1reFuency *eponi-ilit

y

(ontingency

action plan

*emar+o be prepared for all output indicators and prioritized input process indicators !ic required monitorin% over time.

Mi t + P fi i t d d if


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Mita+e Proofing introduced if any

Add Mita+e proofing introduced wit) picture/ diagram if any

Vi l C t l i t d d if


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Visual Controls introduced6 if any

Add iual control introduced wit) picture/ diagram if any foreffecti#e trac+ing of $ and/ or lited in Proce control ytem=

( t l () t i t d d if


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(ontrol ()art introduced if any

Add ()art introduced wit) picture if any for effecti#e trac+ing of $and/ or lited in Proce control ytem=

*eplication !pportunity


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*eplication !pportunity*eplication Standardi


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"eam *eflection

>)at went well >)at could -e -etter

Project Benefit: 'nitial etimate / (!PQ: N@=@@


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Project Benefit: 'nitial etimate / (!PQ: N@=@@Project ame

Blac+ Belt %(andidate&

1inancial Benefit 3t Quarter 4nd Quarter 5rd Quarter 6t) Quarter "otal

/irect savin%s L.

'ncreased revenues L.

(educed costs L.


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(ondition >or+)eet : 'nitial etimate / (!PQ: N@=@@Project ame


1inancial Benefit 1*

2*

3*

4*

(ondition 1*

2*

3*

4*(alculation formula 1*

2*

3*

4*

8*

9*

Appro#al +i%nature

0BB Fame/ate

Campion Fame

/ate

:inance Fame

/ate

(alculation >or+)eet : 'nitial etimate /(!PQ: N@=@@

Project ame


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1inancial Benefit

Appro#al +i%nature

0BB Fame

/ate

Campion Fame

/ate

:inance Fame

/ate

Mahindra Black Belt Project Template - New

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