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Six Sigma Templates

Six Sigma Templates


Six Sigma Templates
Six Sigma Templates
Breakthrough Strategy
Page 5
Step MAIC Focus Action Question
1 Measure CTQ Select CTQ Characteristic
2 Measure CTQ Define Performance Stanars
! Measure CTQ "aliate Measurement System
# $naly%e CTQ &sta'lish Prouct Capa'ility
5 $naly%e CTQ Define Performance (')ecti*es
+ $naly%e CTQ ,entify "ariation Sources Do -e kno- the ma)or family of *ariation.
/ ,mpro*e Screen Potential Causes $re the le*erage CTP0s kno-n.
1 ,mpro*e Stuy 2ey 3elationships
4 ,mpro*e CTP &sta'lish (perating Tolerances
15 Control CTP "aliate Measurement System 6for 70s8
11 Control CTP Determine Process Capa'ility 69 an 70s8
12 Control CTP ,mplement Process Control System Can o')ecti*es 'e consistently met.
Does the selecte CTQ offer high impact ::
;uality< cost or time .
Can state performance stanars satisfy
customer an 'usiness nees.
,s the current measurement system
accepta'le 'y con*entional stanars.
Does the existing capa'ility of this CTQ
nee to 'e impro*e to meet performance
re;uirements.
Do -e kno- the extent to -hich the *ariation
must 'e reuce to meet o')ecti*es.
CTQ an CTP
6Critical to
Process8
CTQ an CTP
6Critical to
Process8
Do -e kno- -hat relationships among the
CTP0s must 'e controlle .
Do -e kno- the functional limits for the
CTP0s.
,s the current measurement systems
accepta'le 'y con*entional stanars for the
CTP0s.
Can process operate -ithin chosen limits to
a + capa'ility.
Breakthrough Strategy
Page +
Know See Tool
Selection critieria an timeframe Decision Matrix
=raphical presentation of re;uirements
P>T an 3?3 *alues =33 Ta'le =age 3?3 spreasheet
Minita'
Picture of @is@ an @ought@ Minita'
,nputs< noise *aria'les
=raphical an ta'ular form
=raphical an ta'ular form
&;uation an graphical
P>T an 3?3 *alues =33 Ta'le =age 3?3 spreasheet
Minita'
Control charts< CTQ yiel information Six Sigma 3eports Six Sigma Macro< control chart option
Brainstorming< pareto< C?& analysis<
process>esign AM&$< C(PQ< 3T9< pu<
9Bnorm
Mean< target< Spec Cimits< functional limits<
re;uire capa'ility
Communication -ith customers< Strat Plan<
Design specifications
Baseline , < Cp< Cpk< Pp< Ppk
Minita' Capa'ility Six Pack an Six Sigma
Macro 3eports
Baseline an target , < Cp< Cpk< Pp< Ppk
Process Map an capa'ilities of each input
*aria'les
Process Map< AM&$< Cause an &ffect
Matrix< Multi*ari chart
Direction of effect an sensiti*ity of selecte
CTP0s -ith respect to ,
Main &ffects Plot< $D("$< (SSe>SSt8<
$utocorrelation< 3egression
Main effects< ,nteractions< clear of
confouning
Main &ffects Plot<,nteraction Plots< $D("$<
(SSe>SSt8< $utocorrelation< 3egression
3egression coefficients an coing
information
Main effects plots< regression< interactions
plot
Baseline , < Cp< Cpk< Pp< Ppk
Minita' Capa'ility Six Pack an Six Sigma
Macro 3eports
Breakthrough Strategy
Page /
Data Location
Simulator< Q$>QC< Manufacturing
Simulator
Sample Data o*er process range Ca'>Aloor
Simulator
Pre*ious outputs
Process unerstaning =rey Matter
Data from prouct capa'ility stuy
Sample Data o*er process range Shop floor
3ational su'groups of continuous ata Shop floor
Continuous an iscrete ata< Spec Cimits
for short term<
3elia'ility an -arranty ata< engineering
ata< Mean< Stanar De*iation< Spec Cimits
for short term
nE 555 su'groups E 155
su'group si%e E 5< recor 9 an 70s for
future use
Arom capa'ility analysis an performance
stanars
SS Project Plan Six Sigma Project Template 09/17/2014
Six Sigma Project Template
Project Name
Group Name Black Belt Name
Department Name Team Members
Project Champion Name
Process Owner Name
Total T!"s Per#orming Process
Total Cost o# Process $%%%"s&
Problem Statement Cost o# De#ect
Provide complete and detailed description
State the Problem'De#ect
State the Defect or Undesired Event
Exclude solutions
Do not include causes
Review with Finance
Define measurement source
Include Baseline data (if available
Include!imeframe
Include conditions surroundin" problem
Project Objecti(e'Desire) State State the Pro#ect $b#ective%Desired State and ma&e sure it lin&s bac& to the Problem Statement
'learl( define and )uantif(
State the Project Objecti(e
*+, Defect Reduction Sou"ht
Include Entitlements - Best Performance
Include available benchmar& data
Bene#its $*%%%"s& Cost Bene#its Client'!mplo+ee Bene#its
Include Shareholder%'ost Benefits FTE Cost Savings Internal/External Client Benefits
Include 'lient Service Benefits - Intrnl%Ext Other Cost Savings
Employee Benefits
Cost Bene#its outsi)e o# Group
Emplo(ee Benefits Revenue
Total Cost Benefits $0
Depen)encies
Si"nificant S(stems Development
.a#or 'apital Investment
External 'onsiderations
Potential to ,e(erage
Other -n#ormation Include an( other information related to the Pro#ect as necessar(
De#ect T!"s (if app/
Description
Description
Can project be performed in 4 months?
Yes No
Project Action Plan
Project Black Belt
Process Owner Date
Wat !ow Wo Wen Deli"era#les
$Action to Take% $Action Steps% $Accounta#le% Start Finis
Critical to Quality Characteristics
Project &a'e(
Project Description(
Project Mana)ers(
Date(
!ow to Satis*+ Wants
Wat te custo'er wants
Total
SIPOC
Fhat o the suppliers pro*ie to my process.
Suppliers Input Output Customers
1 1 Start PointG 1 1
2 2
! 2 1
2 1 2
2 (peration or $cti*ity ! 1
! 1 2
! 1 2 # 1
2 ! 2
! # 5 1
# 1 5 2
2 + + 1
! / 2
1
4
15
11
&n PointG
prouct or ser*ice. steps in the processB eli*er to the customer. performance
Process 6High Ce*el8
Suppliers Inputs Process Outputs Custo'ers
6Deli*era'les from the process8
3e;uirements 3e;uirements
6Pro*iers of the re;uire
resources8
63esources re;uire 'y the
process8
6Top le*el escription of the
acti*ity8
6$nyone -ho recei*es a
eli*era'le from the process8
Process Analysis Worksheet
Process Dame 6? 'ounaries8G
Process (-ner6s8G
Step DoB $cti*ity 3esponsi'le "olume DoB Total hrs D"$ D"$ hrs>
position per -eek ini*iuals per -eek 69>D.8 -eek
618 628 6!8 6#8 658 6+8 6/8 618
SumE
Management Man Metho
Measurement Machine
Material
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
&ffect
698
Material
Brainstorm Potential Root Causes
Rank Potential Root Cause Supporting Data & Analysis? Source? Who? When?
ICommon types of ata an analysis $nalysis escriptionG
Detaile! Process Re"ie# Careful -alkthrough of the process step 'y step to etermine the source< nature an fre;uency of the pro'lem
Process $apping Detaile process flo- analysis to unerstan all the steps of the process< ho- the pro'lem occurs an to ocument the process flo-
%isual Analysis "isual examination of the pro'lem an *isual ocumentation such as igital photos an *ieos
Cause an! &''ect (&"ent) Analysis &xamination of the potential relationship of factors an or e*ent conitions on the pro'lem
Data Collection an! Analysis Measurement of performance from the prouct or process an an analysis of current ata an associate factor effects
A!!itional *ests an! &+periments $itional tests or experiments esigne to unerstan the current situation an etermine the root cause
Pro,lem
Statement-
.unction Deployment $atri+
Outputs/ Outcomes
Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Output 9 Score
g!t 1 2
"nput 1 15 2 1#
"nput 2
"nput 3
"nput 4
"nput 5
"nput 6
"nput 7
"nput 8
"nput 9
"nput 10
"nput 11
"nput 12
Score 15 # 5 5 5 5 5 5 5
"nput#
g!t
Risk Assessment .orm
Cist the Solution or Aailure Moe Se*erity Pro'a'ility Score $ction (-ner Due
Ma)or &lements of 6Fhat can go -rong8 61:158 615 is 6High scores Plan Date
9our Solution Cist each failure moe 15 is Forst *ery pro'a'le8 nee attention8
1BSolution
a8
'8
c8
2B Solution a8
'8
c8
!B Solution a8
'8
Solution &"aluation .orm
Cist 3oot Cause6s8 Cist Solutions J &ffect &stimate Cost Complexity &stimate Benefit 3iskI Priority "aliation.
3oot Cause 1 Solutions 1
J of cost time or sa*ings High (rer Dee
effect of effort to ue to Meium of potential to
solution solution implement solution or solution *erify
-ill ha*e implementation short term. or Co- implmentation effecti*eness
on the long term. impro*ement 1st< 2n< !r of solution
root cause in customer
satisfaction
3oot Cause 2
I Kse 3isk $ssessment Aorm
Data Collection Plan
De'ine What to $easure De'ine 0o# to $easure Who #ill
Sample Plan
Do it?
Type of (perational Measurement Data Tags Deee Data Collection Person6s8 Fhat. Fhere. Fhen. Ho- Many.
Measure Measure Definition or Test Metho to Stratify the Data Metho $ssigne
Dame of 7 or 9 Clear efinition of "isual Data tags are Manual. State Fhat Cocation Ho- The num'er
parameter attri'ute or the measurement inspection efine for the Spreasheet. -ho has measure is for often of ata
or conition iscrete efine in such a or automate measureB Such Computer 'ase. the 'eing ata the points
to 'e ata< -ay as to achie*e test. asG time< ate< etcB responsi'ility. collecte collection ata collecte
measure prouct or repeata'le results Test instruments location< tester< is per sample
process from multiple are efineB line< customer< collecte
ata o'ser*ers 'uyer< operator<
Proceures for etcB
ata collection
are efineB
$easure Relationships
Responses or Outputs (1s) .actors (2s)
Depenent "aria'le KSC CSC Target ,nepenent "aria'le6s8 KSC CSC Target




Root Cause Analysis *imeline
Pro)ect DameG Start DateG +>15>2552
Kse lines an or color 'ars to inicate start an stop ates for each acti*ity
Pase( Acti"it+ Start Date ,n- Date Assi)ne- to( 6/10/2002 6/11/2002 6/12/2002 6/13/2002 6/14/2002 6/15/2002 6/16/2002 6/17/2002
1B Define an
Contain the
Pro'lem
2B Measure the
Pro'lem
!B Perform
3oot Cause
$nalysis
#B Plan an
,mplement
,mpro*ement
5B $ssess
&ffecti*eness of
,mpro*ement
+B Stanari%e
an Control
/B 3eali%e an
3eflect
Root Cause Analysis *imeline
Pro)ect DameG
Pase( Acti"it+ Start Date ,n- Date Assi)ne- to(
1B Define an
Contain the
Pro'lem
2B Measure the
Pro'lem
!B Perform
3oot Cause
$nalysis
#B Plan an
,mplement
,mpro*ement
5B $ssess
&ffecti*eness of
,mpro*ement
+B Stanari%e
an Control
/B 3eali%e an
3eflect
Root Cause Analysis *imeline
6/18/2002 6/19/2002 6/20/2002 6/21/2002 6/22/2002 6/23/2002 6/24/2002 6/25/2002
Root Cause Analysis *imeline
Pro)ect DameG
Pase( Acti"it+ Start Date ,n- Date Assi)ne- to(
1B Define an
Contain the
Pro'lem
2B Measure the
Pro'lem
!B Perform
3oot Cause
$nalysis
#B Plan an
,mplement
,mpro*ement
5B $ssess
&ffecti*eness of
,mpro*ement
+B Stanari%e
an Control
/B 3eali%e an
3eflect
Root Cause Analysis *imeline
6/26/2002 6/27/2002 6/28/2002 6/29/2002 6/30/2002 7/1/2002 7/2/2002 7/3/2002 7/4/2002
Root Cause Analysis *imeline
Pro)ect DameG
Pase( Acti"it+ Start Date ,n- Date Assi)ne- to(
1B Define an
Contain the
Pro'lem
2B Measure the
Pro'lem
!B Perform
3oot Cause
$nalysis
#B Plan an
,mplement
,mpro*ement
5B $ssess
&ffecti*eness of
,mpro*ement
+B Stanari%e
an Control
/B 3eali%e an
3eflect
Root Cause Analysis *imeline
7/5/2002 7/6/2002 7/7/2002 7/8/2002 7/9/2002 7/10/2002
D(& 2L2 template
Page 24
$eplication# ::::: ::::
A B AB 1 2 ! # 5 Sum $*erage
:1 :1 1 21 25 2/ 15 2+B+/
1 :1 :1 !+ !2 !2 155 !!B!!
:1 1 :1 11 14 2! +5 25B55
1 1 1 !1 !5 24 45 !5B55
a*e : 2!B! !5B5 2+B/
a*e M !1B/ 25B5 21B!
effect 1B! :5B5 1B/
A&O.A
Sources SS f MS A A ta'le Stat si
$ 251B! 1 251B!! 5!B14 11B251+ / 5B51
B /5B55 1 /5B55 14B15 11B251+ /
$B 1B!! 1 1B!! 2B121 11B251+ ns
&rror !1B!! 1 !B42
Total !2!B5 11
0,10,SSIO& MOD,L
2
2
Aactorial Design 6-ith up to 5 replicates8
a*e : a*e M
5B5
15B5
25B5
!5B5
#5B5
A ,**ect
a*e : a*e M
22B5
2#B5
2+B5
21B5
!5B5
!2B5
B ,**ect
$ : $ M
5
15
25
!5
#5
AB Interaction
B :
D(& 2L2 template
Page !5
,ntercept 2/B55
$ coefficient #B1++/
B coefficient :2B5
$B coefficient 5
P0,DICTIO& ,Q2ATIO&
$ 1
B 1
9:hat 24B1/
0,SID2ALS
$ctual Pre 3esiual rank Perc N
1 :1 :1 21 25B1! 2B1+/ 1 2B5 :1B4+
2 :1 :1 25 25B1! :5B1!! 1+ //B5 5B/55#
! :1 :1 2/ 25B1! 1B1+/ 5 22B5 :5B/55
# :1 :1 5 5 5B555 / !2B5 :5B#5#
5 :1 :1 5 5 5B555 / !2B5 :5B#5#
1 1 :1 !+ !#B1/ 1B1!! ! 12B5 :1B15
2 1 :1 !2 !#B1/ :2B1+/ 11 1/B5 1B155!
! 1 :1 !2 !#B1/ :2B1+/ 11 1/B5 1B155!
# 1 :1 5 5 5B555 / !2B5 :5B#5#
5 1 :1 5 5 5B555 / !2B5 :5B#5#
1 :1 1 11 25B1! :2B1!! 25 4/B5 1B4+
2 :1 1 14 25B1! :1B1!! 1/ 12B5 5B4!#+
! :1 1 2! 25B1! 2B1+/ 1 2B5 :1B4+
# :1 1 5 5 5B555 / !2B5 :5B#5#
5 :1 1 5 5 5B555 / !2B5 :5B#5#
1 1 1 !1 24B1/ 1B1!! ! 12B5 :1B15
2 1 1 !5 24B1/ 5B1!! + 2/B5 :5B541
! 1 1 24 24B1/ :5B1+/ 15 /2B5 5B54/1
# 1 1 5 5 5B555 / !2B5 :5B#5#
5 1 1 5 5 5B555 / !2B5 :5B#5#
5 5 15 15 25 25
:#B555
:!B555
:2B555
:1B555
5B555
1B555
2B555
!B555
D(& 2L2 template
Page !1
,FF,CTS PLOT
score rank $03456%7 8 score
1B! ! 5B1!!! 5B4+/#2
:5B5 1 5B1++/ :5B4+/#
1B/ 2 5B5 5
:+B5 :#B5 :2B5 5B5 2B5 #B5 +B5 1B5 15B5
5
5B1
5B2
5B!
5B#
5B5
5B+
5B/
5B1
5B4
D(& 2L2 template
Page !2
B : B M
$ : 2+B/ 25
$ M !!B! !5
D(& 2L2 template
Page !!
D(& 2L2 template
Page !#
D(& 2L! template
Page !5
$eplication# ::::: ::::
A B C AB AC BC ABC 1 2 ! # 5 Sum $*erage
618 :1 :1 :1 1 1 1 :1 1 2 ! + 2B55
a 1 :1 :1 :1 :1 1 1 1 2 ! + 2B55
' :1 1 :1 :1 1 :1 1 1 2 ! + 2B55
a' 1 1 :1 1 :1 :1 :1 1 2 ! + 2B55
c :1 :1 1 1 :1 :1 1 1 2 ! + 2B55
ac 1 :1 1 :1 1 :1 :1 1 2 ! + 2B55
'c :1 1 1 :1 :1 1 :1 1 2 ! + 2B55
a'c 1 1 1 1 1 1 1 1 2 ! + 2B55
a*e : 2B55 2B55 2B55 2B55 2B55 2B55 2B55
a*e M 2B55 2B55 2B55 2B55 2B55 2B55 2B55
effect 5B55 5B55 5B55 5B55 5B55 5B55 5B55
2
!
Aactorial Design 6-ith up to 5 replicates8
a*e : a*e M
5B55
5B55
1B55
1B55
2B55
2B55
A ,**ect
a*e : a*e M
5B55
5B55
1B55
1B55
2B55
2B55
B ,**ect
$ : $ M
5B55
5B55
1B55
1B55
2B55
2B55
AB Interaction
B :
a*e : a*e M
5B55
5B55
1B55
1B55
2B55
2B55
C ,**ect
$ : $ M
5B55
5B55
1B55
1B55
2B55
2B55
AC Interaction
C
:
B : B M
5B55
5B55
1B55
1B55
2B55
2B55
BC Interaction
C
:
D(& 2L! template
Page !+
Sources SS f MS A A ta'le Stat sig
$ 5B55 1 5B55 5B55 1B5! ns 5B51
B 5B55 1 5B55 5B55 1B5! ns
C 5B55 1 5B55 5B55 1B5! ns
$B 5B55 1 5B55 5B55 1B5! ns
$C 5B55 1 5B55 5B55 1B5! ns
BC 5B55 1 5B55 5B55 1B5! ns
$BC 5B55 1 5B55 5B55 1B5! ns
&rror 1+B55 1+ 1B55
Total 1+B55 2!
0,10,SSIO& MOD,L
,ntercept 2B55
$ coefficient 5
B coefficient 5
C coefficient 5
$B coefficient 5
$C coefficient 5
BC coefficient 5
$BC coefficient 5
P0,DICTIO& ,Q2ATIO&
$ 1
B 1
C 1
9:hat 2B55
$ : $ M
5B55
5B55
1B55
1B55
2B55
2B55
AB Interaction
B :
$ : $ M
5B55
5B55
1B55
1B55
2B55
2B55
AC Interaction
C
:
B : B M
5B55
5B55
1B55
1B55
2B55
2B55
BC Interaction
C
:
D(& 2L! template
Page !/
D(& 2L! template
Page !1
A&O.A
B : B M
$ : 2B55 2B55
$ M 2B55 2B55
C: CM
$ : 2B55 2B55
$ M 2B55 2B55
C: CM
B : 2B55 2B55
B M 2B55 2B55
B : B M
5B55
5B55
1B55
1B55
2B55
2B55
BC Interaction
C
:
D(& 2L! template
Page !4
B : B M
5B55
5B55
1B55
1B55
2B55
2B55
BC Interaction
C
:
D(& 2L! template
Page #5
Parts per $illion Calculator
*his is a simple sigma le"el calculator
,nter process si)'a le"el9 co'pute PPM
Process Si)'a Le"el 3: +
PPM !B#
Percent 5B555!#J
,nter percent9 co'pute PPM an- process si)'a le"el
Percent 3: 5B555!#J
PPM !B#
Process Sigma Ce*el +B5
,nter DPMO9 co'pute process si)'a le"el
DPMO 3: !B#
Process Sigma Ce*el +B5
,f the percent is less than 1< you must use
the percent sign after the num'er 6eBgB<
5B51J8
Sigma 3e"el (no shi't) Calculator
4O 567 SI8$A S0I.* I4 *0&S& CA3C93A*IO4S
,nter process si)'a le"el9 co'pute PPM
Process Si)'a Le"el 3: +
PPM 5B5
Percent 5B55555J
,nter percent9 co'pute PPM an- process si)'a le"el
Percent :O 1B55J
PPM 15555
Process Si)'a Le"el 3: 2B!2+
,nter DPMO9 co'pute process si)'a le"el
Process Si)'a Le"el 3: #B5
DPM( !B#
Rolle! *hroughput 1iel! Calculator
Step !"#O !"#O/$%000%000
$&'!"#O/$%000%000(
$ )%000 0*00)
0*++)
, $)%000 0*0$)
0*+-)
. $%000 0*00$
0*+++
/ )0 0*0000)
0*++++)
0T;< 5B44#/2
DP$O Calculator
*his template calculates the DP$O using the num,er o' !e'ects6
Total num'er of unitsG 2555
Dum'er of efectsG #
(pportunities for &rror in one unitG 25
DPMO < 15
Dot sure of -hat goes into the units.
The Data Processing Dept super*isor -ants to calculate the DPM( of ata entry errors in her eptB
$ total of 2<555 forms -ere processe that ay< an the super*isor fins # fiels -ith errorB
There are 25 entry fiels on each ata entry formB
Aor this scenarioG
Total num'er of units E 2<555
Dum'er of efects E #
(pportunities for error in one unit E 25
Con"ersion Calculator
Sigma Con*ersion Ta'le
4!!<255 5B555 5B555
415<#55 5B125 5B5#2
14#<#55 5B255 5B51!
1+4</55 5B!/5 5B125
1#1<!55 5B555 5B1+/
154<255 5B+25 5B251
//!<#55 5B/55 5B255
/!#<555 5B1/5 5B242
+41<555 1B555 5B!!!
+#5<+55 1B125 5B!/5
541</55 1B255 5B#1/
5#4</55 1B!/5 5B#51
555<555 1B555 5B555
#55<255 1B+25 5B5#2
#51<!55 1B/55 5B51!
!5#<!55 1B1/5 5B+25
!51<555 2B555 5B++/
2+5<455 2B125 5B/51
22+<+55 2B255 5B/55
145<155 2B!/5 5B/42
151</55 2B555 5B1!!
1!5<!55 2B+25 5B1/5
155<+55 2B/55 5B41/
1#<555 2B1/5 5B451
++<155 !B555 1B555
52<155 !B125 1B5#2
#5<155 !B255 1B51!
!5<#55 !B!/5 1B125
22</55 !B555 1B1+/
1+<155 !B+25 1B251
12<255 !B/55 1B255
1<155 !B1/5 1B242
+<255 #B555 1B!!!
#<!55 #B125 1B!/5
!<555 #B255 1B#1/
2<555 #B!/5 1B#51
1<!55 #B555 1B555
455 #B+25 1B5#2
+55 #B/55 1B51!
#55 #B1/5 1B+25
2!5 5B555 1B++/
115 5B125 1B/51
1!5 5B255 1B/55
15 5B!/5 1B/42
Defects Per
Million
(pportunities
Sigma Ce*el
6Fith 1B5
Sigma
Shift8I
Cpk 6Sigma
Ce*el > !8 Fith
1B5 Sigma ShiftI
!5 5B555 1B1!!
2! 5B+25 1B1/5
1/ 5B/55 1B41/
15 5B1/5 1B451
! +B555 2B555
The ta'le assumes a 1B5 sigma shift 'ecause
processes ten to exhi'it insta'ility of that magnitue
o*er timeB ,n other -ors< although statistical ta'les
inicate that !B# efects > million is achie*e -hen
#B5 process stanar e*iations 6Sigma8 are 'et-een
the mean an the closest specification limit< the
target is raise to +B5 stanar e*iations to
accommoate a*erse process shifts o*er time an
still prouce only !B# efects per million opportunitiesB
Si+ Sigma Pro:ect *imeline
Pro)ect DameG
,D Task Hours Start &n Status
1 Define 1 Fk 25:Sep:51 1:(ct:51 Complete
2 Measure 1/ Fks 2:(ct:51 25:Pan:52 Forking
# Pro)ect Direction Meeting 1 Hrs 22:Pan:52 22:Pan:52
5 $ssign 3oles 5 Min 22:Pan:52 22:Pan:52
+ 3e*ie- Status 15 Min 22:Pan:52 22:Pan:52
/ 3e*ie- Scheule 5 Min 22:Pan:52 22:Pan:52
1 Pro)ect Direction Decision !! Min 22:Pan:52 22:Pan:52
4 Clarify (ptions 15 Min 22:Pan:52 22:Pan:52
15 ,D Decision Maker 2 Min 22:Pan:52 22:Pan:52
11 "ote on (ptions 2 Min 22:Pan:52 22:Pan:52
12 Dialog $ 5 Min 22:Pan:52 22:Pan:52
1! "ote on (ptions 2 Min 22:Pan:52 22:Pan:52
1# Dialog B 5 Min 22:Pan:52 22:Pan:52
15 "ote on (ptions 2 Min 22:Pan:52 22:Pan:52
1+ Decision Maker Decies 5 Min 22:Pan:52 22:Pan:52
1/ $ssign Tasks 5 Min 22:Pan:52 22:Pan:52
11 Fork Tasks 2 Days 22:Pan:52 2#:Pan:52
14 Process Map ? Data Meeting 4+ Min 2#:Pan:52 2#:Pan:52
!1 Fork Tasks 1 Day 2#:Pan:52 25:Pan:52
!4 Tollgate 3e*ie- 1 Hrs 25:Pan:52 25:Pan:52
#5 $naly%e 2 Fks 25:Pan:52 1:Ae':52
#1 AM&$ Meeting 1 42 Min 25:Pan:52 25:Pan:52
55 Fork Tasks # Days 25:Pan:52 !1:Pan:52
51 AM&$ Meeting 2 42 Min !1:Pan:52 !1:Pan:52
+5 Fork Tasks # Days !1:Pan:52 +:Ae':52
+1 AM&$ an Data $nalysis Meeting /1 Min +:Ae':52 +:Ae':52
// Fork Tasks 1 Day +:Ae':52 /:Ae':52
/1 ,mpro*ement Direction Meeting 1 Hrs /:Ae':52 1:Ae':52
41 Tollgate 3e*ie- 1 Hrs 1:Ae':52 1:Ae':52
42 ,mpro*e ! Fks 1:Ae':52 21:Ae':52
11/ Control # Fks 21:Ae':52 21:Mar:52
Comments
1a)e Control Plan
Pa)e( o* o*
1a)e In*or'ation Personnel In*or'ation Docu'ent &o(
=age Dame Department 0e"ision Date(
=age ,D>Serial Dum'er Storage Cocation Superce-es(
=age Type 3esponsi'le Storage Fre=uence+(
0e*erence In*or'ation 3esponsi'le MS$
Cali'ration Proceure
Hanling an Storage
Maintenance
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Date 3esoluton Bias Cinearity Sta'ility
Cali'ration =3?3
Dotes
Date By J3?3 P>T Disc ,nex
Baseline
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Page 52
1 2 ! # 5 + / 1 4 15 11 12 1! 1# 15
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Cause > ,**ect Matri? Cause > ,**ect Matri?
PAM&$ ,nformation Sheet
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PAM&$ 2ey DateG
PAM&$ (rigination DateG
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Core Team Mem'ersG
Potential Aailure Moes an
&ffects $nalysis 6,nformation
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Potential Aailure Moes an
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AM&$
Page 5#
Prepare 'yG Page QQQQ of QQQQ
3esponsi'leG AM&$ Date 6(rig8 QQQQQQQQQQQQQQ 63e*8 QQQQQQQQQQQQQ
Process Step Potential Failure Mo-e Potential Failure ,**ects Potential Causes Current Controls 0esp5 Actions Taken

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ASe*erity
Page 55
&ffect CriteriaG Se*erity of &ffect Define 3anking
15
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-arningB
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"ehicle > item inopera'le< loss of primary functionB Customer *ery issatisfieB
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6less than 155J8 scrappeB "ehicle opera'le< 'ut at a reuce le*el of
performanceB Customer issatisfieB
Minor isruption to prouction lineB $ portion 6less than 155J8 may ha*e to 'e
scrappe 6no sorting8B "ehicle > item opera'le< 'ut some comfort > con*enience
item6s8 inopera'leB Customers experience iscomfortB
Minor isruption to prouction lineB 155J of prouct may ha*e to 'e re-orkeB
"ehicle > item opera'le< 'ut some comfort > con*enience item6s8 opera'le at
reuce le*el of performanceB Customer experiences some issatisfactionB
Minor isruption to prouction lineB The prouct may ha*e to 'e sorte an a
portion 6less than 155J8 re-orkeB Ait > finish > s;ueak > rattle item oes not
conformB Defect notice 'y most customersB
Minor isruption to prouction lineB $ portion 6less than 155J8 of the prouct may
ha*e to 'e re-orke on:line 'ut out:of:stationB Ait > finish > s;ueak > rattle item oes
not conformB Defect notice 'y a*erage customersB
Minor isruption to prouction lineB $ portion 6less than 155J8 of the prouct may
ha*e to 'e re-orke on:line 'ut in:stationB Ait > finish > s;ueak > rattle item oes not
conformB Defect notice 'y iscriminating customersB
A(ccurance
Page 5+
Pro#a#ilit+ o* Failure Possi#le Failure 0ates Cpk 0ankin)
.er+ !i)( R 5B!! 15
Aailure is almost ine*ita'le 1 in ! 4
1 in 1 1
processes that ha*e often faile 1 in 25 /
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pre*ious processes -hich ha*e 1 in #55 5
1 in 2<555 #
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1 in 155<555 2
1
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processes
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ientical processes
1 in 1<555<555 1B+/
ADetection
Page 5/
Detection 0ankin)
Al'ost I'possi#le Test content etects R 15 J of failures 15
.er+ 0e'ote Test content must etect 15 J of failures 4
0e'ote Test content must etect 12B5 J of failures 1
.er+ Low Test content must etect 15 J of failures /
Low Test content must etect 1/B5 J of failures +
Mo-erate Test content must etect 45 J of failures 5
Mo-eratel+ !i) Test content must etect 42B5 J of failures #
!i) Test content must etect 45 J of failures !
.er+ !i) Test content must etect 4/B5 J of failures 2
Al'ost Certain Test content must etect 44B5 J of failures 1
Criteria( Liklioo- te e?istence o* a -e*ect will #e
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Core TeamG Date 6(rig8G
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