LSS Measure Tollgate Templates

8/17/2019 LSS Measure Tollgate Templates

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Lean SixSigmaMeasurePhaseTollgateReview Measure

Phase


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ean x gmaDMAIC Tools and

ActivitiesReview Project Charter

Validate igh!Level ValueStream Ma" and Sco"eValidate Voice o# theCustomer$ Voice o# the %usinessValidate Pro&lem Statementand 'oalsValidate (inancial %ene#itsCreate Communication PlanSelect and Launch TeamDevelo" Project ScheduleCom"lete De#ine Tollgate

Identi#) Root Causes

Reduce List o# Potential RootCausesCon#irm Root Cause to*ut"ut Relationshi"+stimate Im"act o# RootCauses on ,e) *ut"utsPrioriti-e Root CausesValue!Add Anal)sisTa.t Rate Anal)sis/uic. 0insStatistical Anal)sisCom"lete Anal)-e Tollgate

Develo" Potential Solutions

+valuate1 Select1 and*"timi-e %est SolutionsDevelo" 2To!%e3 Value StreamMa"4s5Develo" and Im"lement PilotSolutionIm"lement 6s ProgramDevelo" (ull ScaleIm"lementation PlanCost7%ene#it Anal)sis%enchmar.ingCom"lete Im"rove Tollgate

Develo" S*P3s1 Training

Plan $ Process ControlsIm"lement Solution and*ngoing ProcessMeasurementsCon#irm Attainment o# Project'oalsIdenti#) Project Re"lication*""ortunitiesTrainingCom"lete Control TollgateTransition Project to Process*wner

Project Charter Voice o# the Customer and,ano Anal)sisSIP*C Ma"Project Valuation7R*IC

Anal)sis ToolsRACI and /uad Charts

Sta.eholder Anal)sisCommunication Plan+##ective Meeting ToolsIn8uir) and Advocac) S.illsTime Lines1 Milestones1and 'antt ChartingPareto Anal)sis

Value Stream Ma""ingProcess C)cle+##icienc)7Little3s Law*"erational De#initionsData Collection PlanStatistical Sam"lingMeasurement S)stem

Anal)sis 4MSA5'age R$R,a""a StudiesControl ChartsS"aghetti Diagrams

istograms9ormalit) TestProcess Ca"a&ilit) Anal)sis

Process Constraint ID andTa.t Time Anal)sisCause $ +##ect Anal)sis(M+A

)"othesis Tests7Con#:IntervalsSim"le $ Multi"le Regression

A9*VACom"onents o# VariationCon8uering Product andProcess Com"lexit)/ueuing Theor)

Re"lenishment Pull7,an&anStoc.ing Strateg)Process (low Im"rovementProcess %alancing

Anal)tical %atch Si-ingTotal Productive MaintenanceDesign o# +x"eriments 4D*+5

Solution Selection MatrixPiloting and Simulation0or. Control S)stemSetu" reductionPugh MatrixPull S)stem

Mista.e!Proo#ing7;ero De#ectsStandard *"eratingProcedures 4S*P3s5Process Control PlansVisual Process Control ToolsM'PP

Statistical Process Controls4SPC5Solution Re"licationVisual 0or."laceMetricsProject Transition ModelTeam (eed&ac. Session

Value Stream Ma" (low

Identi#) ,e) In"ut1 Processand *ut"ut MetricsDevelo" *"erationalDe#initionsDevelo" Data Collection PlanValidate MeasurementS)stemCollect %aseline DataDetermine Process Ca"a&ilit)Com"lete Measure Tollgate

Defne Measure

Analyze

Improve

Control


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Project Charter

Pro&lem= Descri&e "ro&lem in non!technical termsStatement should ex"lain wh) "roject is im"ortant> wh)wor.ing on it is a "riorit)

'oal= 'oals communicate ?&e#ore@ and ?a#ter@ conditionsShi#t mean1 variance1 or &othShould im"act cost1 time1 8ualit) dimensions

+x"ress goals using SMART criteria

S"eci#ic1 Measura&le1 Attaina&le1 ResourceRe8uirements1 Time %oundaries+x"lain leverage and strategic im"lications 4i# an)5

Problem/Goal Statement

Tollgate Review Schedule

Financial Impact

Team

State #inancial im"act o# "roject+x"ensesInvestments 4inventor)1 ca"ital1 A7R5Revenues

Se"arate ?hard@ #rom ?so#t@ dollarsState #inancial im"act o# leverage o""ortunities 4#uture"rojects5

P+S 9ame Project +xecutive S"onsor 4i# di##erent #rom PS5PS 9ame Project S"onsor7Process *wner DC 9ame De"lo)ment Cham"ion'%7%% 9ame 'reen %elt7%lac. %eltM%% 9ame Master %lac. %elt

Core Team Role B Contri&: LSS TrainingTeam Mem&er SM+ E%Team Mem&er < TM '%Team Mem&er F SM+ PS

+xtended TeamTeam Mem&er %(M 9ot TrainedTeam Mem&er < IT 9ot Trained

Review high!level schedule milestones here=Phase Com"letionsTollgate Reviews

Tollgate Scheduled Revised CompleteDe#ine= 7 7 ! 7 7Measure= 7 7 7 7 7 7

Anal)-e= 7 7 7 7 7 7Im"rove= 7 7 7 7 7 7Control= 7 7 7 7 7 7

International Standards #or Lean Six

Enter Key Slide Take Away (Key oint! "ere

F


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Data Collection Plan

(or each "er#ormance measure 4E51 u"date a data collection "lanInclude MSA measure "lan 4'antt chart1 MS "roject "lan is *"tional5

Add (inancial measure "lan i# se"arate #rom "er#ormance E

Add an) Time Stud) or other data collection "lans #or Value Stream Ma"Sam"le Si-e CalculationGse additional slides i# needed

Per ormance Measure

Operational

Defnition

Data Sourceand Location

How illData !e

Collected

"o illCollect Data

"en ill Data!e Collected

SampleSize

Stratifcation #actors

How willdata $e

used%

VOC

MSA

Process

VSM

Financials

Others



H


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*"erational De#initions

E Continuous data 4Process start7sto" and c)cle time &oundaries4such as the unit o# measure 4ex minutes51 the unit 4the thing )ou aremeasuring51 will )ou include wee.ends1 holida)s1 non!&usinesshours 5E Discrete data 4De#ine Success7De#ect or other attri&ute values)ou will measure

The su&grou"s values or !#actor grou"ings )ou will use on )our"roject data collection*ther uni8ue terms that a""l) to )our "roject that re8uire clear

o"erational de#initionsGse additional slides as needed to com"lete )our o"erationalde#initions



6


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MSA Conclusions

The measurement s)stems are acce"ta&le: The data is considered to have no "otential #orsigni#icant error: 9eed to &e care#ul to a""ro"riatel) use the data during the Anal)-e Phase:

Type ofMeasurement

ErrorDescription Considerations to this Project

Discrimination(resolution

The a!ility of the measurementsystem to di"ide into #datacate$ories%

&or' hrs can !e measured to )*+hrs) Tool usa$e measure to ,- * min)

.ias The di/erence !et0een an o!ser"eda"era$e measurement result and areference "alue

1o !ias - &or' hours and radar start-stop times consistent throu$hpopulation)

Sta!ility The chan$e in !ias o"er time 1o !ias of 0or' hrs 2 radar usa$edata)

3epeata!ility The e4tent "aria!ility is consistent 1ot an issue) 5a!or and radar usa$eis historical and felt to !e accurateenou$h for insi$ht and analysis)

3eproduci!ility Di/erent appraisers produceconsistent results

3emar's in usa$e data deemed notreproduci!le6 not used in determinin$0hich radars 0ere used in each op

Variation The di/erence !et0een parts n7a to this process)



J


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%aseline %asic Statistics

The current "rocess hasa non!normal distri&utionwith the P!Value K : 6&ut does have a normal&ell!sha"e:

Since the mean andmedian are the same inda)s 4< 5 N7! :6 da)s1we will not trans#ormdata:

The range is F6 and thestandard deviation is


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%aseline Process Ca"a&ilit)


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Sigma Calculator=Continuous Data




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Sigma Calculator=Discrete Data




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/uic. 0in DocumentationTem"late

#$ Root Cause% QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ&$ ' vious Solution% )))))))))))))))))))))))))))))))))))))))))) *$ +ow or ,o Cost% )))))))))))))))))))))))))))))))))))))))))) -$ +ow Risk% QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ.$ /mplementation lan% QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ0$ Stakeholder (s! Approval% QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ

Process 9ame= QQQQQQQQQQQQQQQQQQ Process Lead= QQQQQQQQQQQQQQQQQQQ Process *wner= QQQQQQQQQQQQQQQQQQQQQQ Start Date= QQQQQQQQQQQQQQ

Process Area= QQQQQQQQQQQQQQQQQQQQQQQQ Sto" Date= QQQQQQQQQQQQQQ

%ene#its= QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ

6sH!Ste" Setu" ReductionInventor) ReductionMSA Im"rovementsPrice reductionsReduced D*09TIM+49VA ste"s or wor.5Pull S)stem,ai-en events*ther




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Sources o# 0aste

Sources o# 0aste

,1A

2e3ect 'verproduction Transportation

4aiting/nventoryMotion

Area #

Su& area

Area #

Su& area

Area #Su& area

rocessing

Area #

Su& area

Area #Su& area

Area #

Su& area

< Insert your wastepercentage as shown

in pie chart >



<


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Swim LaneProcess Ma"

ClientContact

Client"R

Admin

ClientMgr

lacesin3ormation

into "Rdata ase

Sends Emailto Admin

Sends e5itdate to /T6telecom 73acilities

Re8veri3ies with mgr onemployee9s e5it status

,TAdmin

Email1endor

:tilize e8mail vendor9swe tool to su mit delete

re;uest to vendor

SendsEmail toAdmin


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Value Stream Ma"Current State

Order Mgmt Supervisor

DIST Order MgmtOrder MgmtOrder Mgmt Order Mgmt

P7T < min

+rror Rate


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%usiness Im"act

State #inancial im"act o# #uture "roject leverage o""ortunitiesSe"arate ?hard or T)"e @ #rom ?so#t T)"e < or F@ dollars

Annual Estimate Replicated Estimate

RevenueEnhancement

• Type 1 : ?• Type 2: ?• Type 3 : ?

• Type 1 : ?• Type 2: ?• Type 3 : ?

ExpensesReduction

• Type 1 : ?• Type 2: ?• Type 3 : ?

• Type 1 : ?• Type 2: ?• Type 3 : ?

Loss Reduction • Type 1 : ?• Type 2: ?• Type 3 : ?

• Type 1 : ?• Type 2: ?• Type 3 : ?

Cost Avoidance • Type 1 : ?• Type 2: ?• Type 3 : ?

• Type 1 : ?• Type 2: ?• Type 3 : ?

Total Savings • Type 1 : ?• Type 2: ?• Type 3 : ?

• Type 1 : ?• Type 2: ?• Type 3 : ?

6International Standards #or Lean Six



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%usiness Im"act Details

T)"e = Descri&e the chain o# causalit) that shows how )ou determined the T)"e savings: 4tell the stor) withcause e##ect relationshi"s1 on how the "ro"osed change should create the desired #inancial result 4savings5 in)our "roject 5Show the #inancial calculation savings and assum"tions used:

Assum"tion 4i:e: source o# data1 clear *"erational De#initions 5 Assum"tion < 4i:e: hourl) rate N incremental &ene#it cost N travel5

T)"e


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Current Status

,e) actionscom"letedIssuesLessons

learnedCommunication1team &uilding1organi-ational

activities

OInternational Standards #or Lean Six



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9ext Ste"s

,e) actionsPlanned Lean Six Sigma Tool use /uestions to answer %arrier7ris. mitigation activities




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Sign *##

I concur that the Measure "hase was success#ull) com"leted onMM7DD7EEEEI concur the "roject is read) to "roceed to next "hase= Anal)-e

Enter 1ame ereDe"lo)ment Cham"ionnter 1ame ere

inancial Re"resentative

nter 1ame erereen %elt7%lac. %eltEnter 1ame

ereMaster %lac. %elt

Enter 1ame ereS"onsor 7 Process *wner




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Toll$ate 3e"ie0s.ac'up Slides

' o ( o r w a r d

0 a i t ! ' o %a c .

a l t ! o l dD

M

A

I

C


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MeasureTollgate Chec.list

Has a more detailed &alue Stream 'ap (een completed to (etter understand the process and pro(lem) and *here in the process the root causes might reside+Has the team conducted a ,alue$added and c%cle time anal%sis) identif%ing areas*here time and resources are de,oted to tasks not critical to the customer+Has the team identified the specific input -./) process -./) and output -%/ measuresneeding to (e collected for (oth effecti,eness and efficienc% categories -i0e0 1ualit%)Speed) and Cost measures/+Has the team de,eloped clear) unam(iguous operational definitions for eachmeasurement and tested them *ith others to ensure clarit%2consistent interpretation+Has a clear) reasona(le choice (een made (et*een gathering ne* data or takingad,antage of e.isting data alread% collected (% the organi ation+Has an appropriate sample si e and sampling fre uenc% (een esta(lished to ensure,alid representation of the process *e re measuring+Has the measurement s%stem (een checked for repeata(ilit% and reproduci(ilit%)

potentiall% including training of data collectors+Has the team de,eloped and tested data collection forms or check sheets *hich areeas% to use and pro,ide consistent) complete data+Has (aseline performance and process capa(ilit% (een esta(lished+ Ho* large is thegap (et*een current performance and the customer -or pro ect/ re uirements+Has the team (een a(le to identif% an% complete 71uick 8ins +Ha,e an% 9ai en opportunities (een identified to accelerate momentum and results+Ha,e ke% learning-s/ to$date re uired an% modification of the Pro ect Charter+ If so)ha,e these changes (een appro,ed (% the Pro ect Sponsor and the 9e%Stakeholders+Ha,e an% ne* risks to pro ect success (een identified) added to the :isk 'itigationPlan) and a mitigation strateg% put in place+

Toll$ate3e"ie0

Toll$ate3e"ie0

S t o "

*ey Delivera$les GDetailed Value StreamMap(sData Collection PlanMeasurement Collection3esultsProcess Capa!ility 3esultsCurrent %aseline Process

Per#ormanceBuic' &ins6 if applica!le

denti cation of @aiHenOpportunities6 if applica!le3e ned Charter6 asnecessaryIpdated 3is' Miti$ation Plan

Delivera&les G"loaded to

Central Storage Location orDe"lo)ment ManagementS)stem:


22/38ime or Cost?fficienc% issue identified in the Pro(lem Statement/ is (eing seen+

Has the team (een a(le to identif% an% additional 71uick 8ins +

Ha,e learnings to$date re uired modification of the Pro ect Charter+ If so) ha,ethese changes (een appro,ed (% the Pro ect Sponsor and the 9e% Stakeholders+

Ha,e an% ne* risks to pro ect success (een identified) added to the :isk'itigation Plan) and a mitigation strateg% put in place+

Toll$ate3e"ie0

Toll$ate3e"ie0

S t o "

Deli"era!lesG5ist of Potential 3oot causes

PrioritiHed 5ist of Validated3oot Causes

Additional #Buic' &ins%6 ifapplica!le

3e ned Charter6 as necessary

Ipdated 3is' Miti$ation PlanDelivera&les G"loaded to CentralStorage Location or De"lo)mentManagement S)stem

as the team identi#ied the .e) #actors 4critical 3s5 that have the &iggest im"act on

"rocess "er#ormance ave the) validated the root causes


23/38%onacorsi Consultin


24/38%onacorsi Consultin


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Attitude Charting $ ,e)Constituenc) Ma" 4*"tional5

Critical massmust e won8overB




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Sam"le Si-e=Continuous Data 4*"tional5




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Sam"le Si-e=Discrete Data 4*"tional5



<


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Measurement S)stems Anal)sis 4MSA5 4*"tional5

Measurement s)stem isacce"ta&le with the TotalB Contri&ution K B

P e r c e n t

Part-to-Part3eprod3epeatJa$e 323

+:

:

S a

:):: 5C5 :

Part>:?;=<

erator8*

Components o -ariation

+ C"art $y Operator

.$ar C"art $y Operator

+esponse $y Part

+esponse $y Operator

Operator / Part Interaction

0a,e +1+ 2A3O-A4 or +esponseGage R R

!"ontributionSource #ar"omp $o% #ar"omp&Total Gage R&R 0 0015!"6 3 #0 Re$eata%ilit 0 000556# 1 2" Re$roduci%ilit 0 0010330 2 40 O$erator 0 000341! 0 #" O$erator'(art 0 0006"12 1 61(art)To)(art 0 041424# "6 30Total *ariation 0 0430143 100 00

Stud *ar +Stud *arSource Std,ev -S,. -6 ' S,. -+S*.Total Gage R&R 03"!#0 0 23"22 1" 22 Re$eata%ilit 0 0235"4 0 14156 11 3! Re$roduci%ilit 0 032140 0 1"2!4 15 50 O$erator 0 01!4!! 0 110"3 ! "1 O$erator'(art 0 0262"0 0 15##4 12 6!(art)To)(art 0 203531 1 2211! "! 13Total *ariation 0 20#3"" 1 2443" 100 00

/um%er o ,istinct Categories = #



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l ) l


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Pro&a&ilit) Plot4*"tional5

9:8+8:*+*:>+>:

??)?

??

?+

?:

;:=::

+

>

:)>

5)6

P e r c e n t

:)8;:

ue :)8?=

1ormal - ?+ CEPro$a$ility Plot of Anderson7Darlin, 3ormality



F

l h


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Control Chart4*"tional5

The current &aselinedeliver) time is sta&leover time with &oth theMoving Range 4MR54F:


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PDCA4*"tional5

Plan=

Do=

Chec.=

Act=

lan

2o

Check

Act



F<


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6s4*"tional5

Sort

Set *rder

Shine

Standardi-e

Sustain



FF

% h A l) i


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%enchmar. Anal)sis4*"tional5

%ased on the in#ormation a&ove1 what is the "er#ormance o&jectiveUReduce de#ects &) BReduce long!term DPM* #rom to :Im"rove short!term ; #rom to :

UI# )ou do not &enchmar.1 "er#ormance standards are &ased on=(or a "rocess with ≤ F sigma level1 decrease B de#ects &) x:(or a "rocess with F sigma level1 decrease B de#ects &)


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,e) %u)ing (actor Anal)sis4*"tional5



F6

S "l V l S


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Sam"le Value StreamMa""ing S)m&ols 4*"tional5

Machining C7T FJ SecSet G" Time O Min

G"time JB

rocess o5

2ata o5

IDueue

/nventory

#

ersonnel

=low(/n3ormation!

Electronic/n3ormation

Sign '33 oint

ush Systems

Truck Shipment

1uotes

SupplierCustomer

=low( hysical!

hysical ull

roFecturst

SupermarketReplenishment

Kan anStation

aper Kan an

Electronic2ata

System @ I @ A=/=' +ane

hysicalTransport


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>o Affice Parking Lot ? S>

&ault

-finance/

Suppl%

:oom

-paper andoffice supplies/

:ecords

:oom

-Arder'anagement/

A' Supr Affice

:eception

?ngineering Affices

Cafeteria:estrooms

@o%er

Arder>aker !

Arder>aker #

Arder>aker 3

Arder?ntr% !

Arder?ntr% #

Arder?ntr% 3

CC &al

#

CC &al3

CC &al!

A' LeadPrinter) @a.

C o pi e r Indicates an in!&ox

or out&ox wherewor. 4#orms7in#ormation5 waitsto &e wor.ed on ortrans#erred

Planning

Scheduling

Lines indicate"a"er7in#ormationtravel=

! 9o set "ath

! Lots o# rewor.

S"aghetti Diagram4*"tional5



FO

AS!IS P M ""i


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AS!IS Process Ma""ingS)m&ols 4*"tional5


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LSS Measure Tollgate Templates