Six Sigma Templates

Six Sigma Templates

Six Sigma Templates
Six Sigma Templates
Breakthrough Strategy
Step MAIC Focus Action Question
1 Measure CTQ Select CTQ Characteristic
Does the selected CTQ offer high impact --
quality, cost or time ?
2 Measure CTQ Define Performance Standards
Can stated performance standards satisfy
customer and business needs?
3 Measure CTQ Validate Measurement System
Is the current measurement system
acceptable by conventional standards?
4 Analyze CTQ Establish Product Capability
Does the existing capability of this CTQ need
to be improved to meet performance
requirements?
5 Analyze CTQ Define Performance Objectives
Do we know the extent to which the variation
must be reduced to meet objectives?
6 Analyze CTQ Identify Variation Sources Do we know the major family of variation?
7 Improve
CTQ and CTP
(Critical to
Process)
Screen Potential Causes Are the leverage CTP's known?
8 Improve
CTQ and CTP
(Critical to
Process)
Study Key Relationships
Do we know what relationships among the
CTP's must be controlled ?
9 Improve CTP Establish Operating Tolerances
Do we know the functional limits for the
CTP's?
10 Control CTP Validate Measurement System (for X's)
Is the current measurement systems
acceptable by conventional standards for the
CTP's?
11 Control CTP Determine Process Capability (Y and X's)
Can process operate within chosen limits to
a 6s capability?
12 Control CTP Implement Process Control System Can objectives be consistently met?
Page 5
Breakthrough Strategy
Know See Tool
Selection critieria and timeframe Decision Matrix
Brainstorming, pareto, C&E analysis,
process/design FMEA, COPQ, RTY, dpu,
Y.norm
Mean, target, Spec Limits, functional limits,
required capability
Graphical presentation of requirements
Communication with customers, Strat Plan,
Design specifications
P/T and R&R values GRR Table Gage R&R spreadsheet
Baseline m, s, Cp, Cpk, Pp, Ppk
Minitab Capability Six Pack and Six Sigma
Macro Reports
Minitab
Baseline and target m, s, Cp, Cpk, Pp, Ppk Picture of "is" and "ought" Minitab
Inputs, noise variables
Process Map and capabilities of each input
variables
Process Map, FMEA, Cause and Effect
Matrix, Multivari chart
Direction of effect and sensitivity of selected
CTP's with respect to m, s
Graphical and tabular form
Main Effects Plot, ANOVA, e (SSe/SSt),
Autocorrelation, Regression
Main effects, Interactions, clear of
confounding
Graphical and tabular form
Main Effects Plot,Interaction Plots, ANOVA,
e (SSe/SSt), Autocorrelation, Regression
Regression coefficients and coding
information
Equation and graphical
Main effects plots, regression, interactions
plot
P/T and R&R values GRR Table Gage R&R spreadsheet
Baseline m, s, Cp, Cpk, Pp, Ppk
Minitab Capability Six Pack and Six Sigma
Macro Reports
Minitab
Control charts, CTQ yield information Six Sigma Reports Six Sigma Macro, control chart option
Page 6
Breakthrough Strategy
Data Location
Continuous and discrete data, Spec Limits
for short term,
Simulator, QA/QC, Manufacturing
Reliability and warranty data, engineering
data, Mean, Standard Deviation, Spec Limits
for short term
Simulator
Sample Data over process range Lab/Floor
n= 500 subgroups = 100 subgroup
size = 5, record Y and X's for future use
Simulator
From capability analysis and performance
standards
Previous outputs
Process understanding Grey Matter
Data from product capability study
Sample Data over process range Shop floor
Rational subgroups of continuous data Shop floor
Page 7
Six Sigma Project Template
Project Name
Group Name Black Belt Name
Department Name Team Members
Project Champion Name
Process Owner Name
Total FTE's Performing Process
Total Cost of Process (000's)
Problem Statement
Provide complete and detailed description
State the Defect or Undesired Event
Exclude solutions
Do not include causes
Review with Finance
Define measurement source
Include Baseline data (if available)
IncludeTimeframe
Include conditions surrounding problem
Project Objective/Desired State State the Project Objective/Desired State and make sure it links back to the Problem Statement
Clearly define and quantify
70% Defect Reduction Sought
Include Entitlements - Best Performance
Include available benchmark data
Benefits ($000's)
Include Shareholder/Cost Benefits
Include Client Service Benefits - Intrnl/Ext
Employee Benefits
Dependencies
Significant Systems Development
Major Capital Investment
External Considerations
Potential to Leverage
Other Information Include any other information related to the Project as necessary
Cost Benefits outside of Group
State the Problem/Defect
Other Cost Savings
Description:
State the Project Objective
Total Cost Benefits $0
Employee Benefits
Client/Employee Benefits
Internal/External Client Benefits
Cost of Defect
Cost Benefits
Description:
Revenue
FTE Cost Savings
Defect FTE's (if app.)
Can project be performed in 4 months?
Yes No
SS Project Plan Six Sigma Project Template 5/30/2014
What How Who
(Action to Take) (Action Steps) (Accountable) Start Finish
Project Action Plan
Project
Process Owner
When Deliverables
Black Belt
Date
Project Name:
Project Description:
Project Managers:
Date:
How to Satisfy Wants
What the customer wants
Total
Critical to Quality Characteristics
Suppliers Input Process (High Level) Output Customers
1 1 Start Point: 1 1
2 2
3 2 1
2 1 2
2 3 1
3 1 2
3 1 2 4 1
2 3 2
3 4 5 1
4 1 5 2
2 6 6 1
3 7 2
8
9
10
11
End Point:
Operation or Activity
Who are the customers
SIPOC
Who are the What do the suppliers provide to my process? What are the start and end What product or service does the process
Suppliers Inputs Outputs
(Providers of the required
resources)
(Resources required by the
process) (Deliverables from the process)
Requirements Requirements
Process Customers
(Top level description of the
activity)
(Anyone who receives a
deliverable from the process)
Process Name (& boundaries):
Process Owner(s):
Step No. Activity Responsible Volume No. Total hrs NVA NVA hrs/
position per week individuals per week (Y/N?) week
(1) (2) (3) (4) (5) (6) (7) (8)
Sum=
Process Analysis Worksheet
Management Man Method
Measurement Machine
Material
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Cause
Effect
(Y)
Method
Material
Cause
Brainstorm Potential Root Causes
Problem
Statement:
Rank Potential Root Cause Supporting Data & Analysis?* Source? Who? When?
*Common types of data and analysis Analysis description:
Detailed Process Review Careful walkthrough of the process step by step to determine the source, nature and frequency of the problem
Process Mapping Detailed process flow analysis to understand all the steps of the process, how the problem occurs and to document the process flow
Visual Analysis Visual examination of the problem and visual documentation such as digital photos and videos
Cause and Effect (Event) Analysis Examination of the potential relationship of factors and or event conditions on the problem
Data Collection and Analysis Measurement of performance from the product or process and an analysis of current data and associated factor effects
Additional Tests and Experiments Additional tests or experiments designed to understand the current situation and determine the root cause
Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Output 9
Inputs
Wght Wght 1 2
Input 1 10 2
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
Input 8
Input 9
Input 10
Input 11
Input 12
Score 10 4 0 0 0 0 0 0 0
Outputs/ Outcomes
Function Deployment Matrix
Score
14
Function Deployment Matrix
Risk Assessment Form
List the Solution or Failure Mode Severity Probability Score Action Owner Due
Major Elements of (What can go wrong) (1-10) (10 is (High scores Plan Date
Your Solution List each failure mode 10 is Worst very probable) need attention)
1.Solution
a)
b)
c)
2. Solution a)
b)
c)
3. Solution a)
b)
Solution Evaluation Form
List Root Cause(s) List Solutions % Effect Estimated Cost Complexity Estimated Benefit Risk* Priority Validation?
Root Cause 1 Solutions 1
% of cost time or savings High Order Need
effect of effort to due to Medium of potential to
solution solution implement solution or solution verify
will have implementation short term? or Low implmentation effectiveness
on the long term? improvement 1st, 2nd, 3rd of solution
root cause in customer
satisfaction
Root Cause 2
* Use Risk Assessment Form
Data Collection Plan
Who will
Do it?
Type of Operational Measurement Data Tags Needed Data Collection Person(s) What? Where? When? How Many?
Measure Measure Definition or Test Method to Stratify the Data Method Assigned
Name of X or Y Clear definition of Visual Data tags are Manual? State What Location How The number
parameter attribute or the measurement inspection defined for the Spreadsheet? who has measure is for often of data
or condition discrete defined in such a or automated measure. Such Computer based? the being data the points
to be data, way as to achieve test? as: time, date, etc. responsibility? collected collection data collected
measured product or repeatable results Test instruments location, tester, is per sample
process from multiple are defined. line, customer, collected
data observers buyer, operator,
Procedures for etc.
data collection
are defined.
Define What to Measure Define How to Measure Sample Plan
Measure Relationships
Responses or Outputs (Ys) Factors (Xs)
Dependent Variable USL LSL Target Independent Variable(s) USL LSL Target




Project Name: Start Date: 6/10/2002
Use lines and or color bars to indicate start and stop dates for each activity
Phase: Activity Start Date End Date Assigned 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
1. Define and
Contain the
Problem
2. Measure the
Problem
3. Perform
Root Cause
Analysis
4. Plan and
Implement
Improvement
5. Assess
Effectiveness of
Improvement
6. Standardize
and Control
7. Realize and
Reflect
Root Cause Analysis Timeline
Project Name:
Phase: Activity Start Date End Date Assigned to:
1. Define and
Contain the
Problem
2. Measure the
Problem
3. Perform
Root Cause
Analysis
4. Plan and
Implement
Improvement
5. Assess
Effectiveness of
Improvement
6. Standardize
and Control
7. Realize and
Reflect
Root Cause Analysis Timeline
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 Timeline
Project Name:
Phase: Activity Start Date End Date Assigned to:
1. Define and
Contain the
Problem
2. Measure the
Problem
3. Perform
Root Cause
Analysis
4. Plan and
Implement
Improvement
5. Assess
Effectiveness of
Improvement
6. Standardize
and Control
7. Realize and
Reflect
Root Cause Analysis Timeline
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 Timeline
Project Name:
Phase: Activity Start Date End Date Assigned to:
1. Define and
Contain the
Problem
2. Measure the
Problem
3. Perform
Root Cause
Analysis
4. Plan and
Implement
Improvement
5. Assess
Effectiveness of
Improvement
6. Standardize
and Control
7. Realize and
Reflect
Root Cause Analysis Timeline
7/5/2002 7/6/2002 7/7/2002 7/8/2002 7/9/2002 7/10/2002
Root Cause Analysis Timeline
DOE 2^2 template
2
2
Factorial Design (with up to 5 replicates)
Replications ----- ----
A B AB 1 2 3 4 5 Sum Average
-1 -1 1 28 25 27 80 26.67
1 -1 -1 36 32 32 100 33.33
-1 1 -1 18 19 23 60 20.00
1 1 1 31 30 29 90 30.00
ave - 23.3 30.0 26.7
ave + 31.7 25.0 28.3
effect 8.3 -5.0 1.7
Sources SS df MS F F table Stat sig ? a
A 208.3 1 208.33 53.2 11.2586 * 0.01
B 75.00 1 75.00 19.1 11.2586 *
AB 8.33 1 8.33 2.13 11.2586 ns
Error 31.33 8 3.92
Total 323.0 11
27.50
ANOVA
REGRESSION MODEL
Intercept
0.0
10.0
20.0
30.0
40.0
ave - ave +
A Effect
22.0
24.0
26.0
28.0
30.0
32.0
ave - ave +
B Effect
0.0
10.0
20.0
30.0
40.0
A - A +
AB Interaction
B -
B +
Page 33
DOE 2^2 template
4.167
-2.5
0
A 1
B 1
Y-hat 29.17
Actual Pred Residual rank Perc Z
1 -1 -1 28 25.8 2.167 1 2.5 -1.96
2 -1 -1 25 25.8 -0.833 16 77.5 0.755
3 -1 -1 27 25.8 1.167 5 22.5 -0.755
4 -1 -1 0 0 0.000 7 32.5 -0.454
5 -1 -1 0 0 0.000 7 32.5 -0.454
1 1 -1 36 34.2 1.833 3 12.5 -1.15
2 1 -1 32 34.2 -2.167 18 87.5 1.15
3 1 -1 32 34.2 -2.167 18 87.5 1.15
4 1 -1 0 0 0.000 7 32.5 -0.454
5 1 -1 0 0 0.000 7 32.5 -0.454
1 -1 1 18 20.8 -2.833 20 97.5 1.96
2 -1 1 19 20.8 -1.833 17 82.5 0.935
3 -1 1 23 20.8 2.167 1 2.5 -1.96
4 -1 1 0 0 0.000 7 32.5 -0.454
5 -1 1 0 0 0.000 7 32.5 -0.454
1 1 1 31 29.2 1.833 3 12.5 -1.15
2 1 1 30 29.2 0.833 6 27.5 -0.598
3 1 1 29 29.2 -0.167 15 72.5 0.598
4 1 1 0 0 0.000 7 32.5 -0.454
5 1 1 0 0 0.000 7 32.5 -0.454
B coefficient
AB coefficient
PREDICTION EQUATION
RESIDUALS
A coefficient
-4.000
-3.000
-2.000
-1.000
0.000
1.000
2.000
3.000
0 5 10 15 20 25
Page 34
DOE 2^2 template
score rank (R-0.5)/nz score
8.3 3 0.833 0.96742
-5.0 1 0.167 -0.9674
1.7 2 0.5 0
EFFECTS PLOT
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
-10.0 -5.0 0.0 5.0 10.0
Series1
Page 35
DOE 2^2 template
B - B +
A - 26.7 20
A + 33.3 30
Page 36
DOE 2^2 template
25
Page 37
DOE 2^3 template
2
3
Factorial Design (with up to 5 replicates)
Replications ----- ----
A B C AB AC BC ABC 1 2 3 4 5 Sum Average
(1) -1 -1 -1 1 1 1 -1 1 2 3 6 2.00
a 1 -1 -1 -1 -1 1 1 1 2 3 6 2.00
b -1 1 -1 -1 1 -1 1 1 2 3 6 2.00
ab 1 1 -1 1 -1 -1 -1 1 2 3 6 2.00
c -1 -1 1 1 -1 -1 1 1 2 3 6 2.00
ac 1 -1 1 -1 1 -1 -1 1 2 3 6 2.00
bc -1 1 1 -1 -1 1 -1 1 2 3 6 2.00
abc 1 1 1 1 1 1 1 1 2 3 6 2.00
ave - 2.00 2.00 2.00 2.00 2.00 2.00 2.00
ave + 2.00 2.00 2.00 2.00 2.00 2.00 2.00
effect 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00
0.50
1.00
1.50
2.00
2.50
ave
-
ave
+
A Effect
0.00
0.50
1.00
1.50
2.00
2.50
ave - ave +
B Effect
0.00
0.50
1.00
1.50
2.00
2.50
A - A +
AB Interaction
B -
B +
0.00
0.50
1.00
1.50
2.00
2.50
ave
-
ave
+
C Effect
0.00
0.50
1.00
1.50
2.00
2.50
A - A +
AC Interaction
C-
C+
0.00
0.50
1.00
1.50
2.00
2.50
B - B +
BC Interaction
Page 38
DOE 2^3 template
Sources SS df MS F F table Stat sig ? a
A 0.00 1 0.00 0.00 8.53 ns 0.01
B 0.00 1 0.00 0.00 8.53 ns
C 0.00 1 0.00 0.00 8.53 ns
AB 0.00 1 0.00 0.00 8.53 ns
AC 0.00 1 0.00 0.00 8.53 ns
BC 0.00 1 0.00 0.00 8.53 ns
ABC 0.00 1 0.00 0.00 8.53 ns
Error 16.00 16 1.00
Total 16.00 23
2.00
0
0
0
0
0
0
0
A 1
B 1
C 1
Y-hat 2.00
ABC coefficient
REGRESSION MODEL
Intercept
A coefficient
B coefficient
PREDICTION EQUATION
C coefficient
AB coefficient
AC coefficient
BC coefficient
Page 39
DOE 2^3 template
Page 40
DOE 2^3 template
ANOVA
B - B +
A - 2.00 2.00
A + 2.00 2.00
C- C+
A - 2.00 2.00
A + 2.00 2.00
C- C+
B - 2.00 2.00
B + 2.00 2.00
C-
C+
Page 41
DOE 2^3 template
C+
Page 42
This is a simple sigma level calculator
Enter process sigma level, compute PPM
Process Sigma Level -> 6
PPM 3.4
Percent 0.00034%
Enter percent, compute PPM and process sigma level
If the percent is less than 1, you must use
the percent sign after the number (e.g.,
0.01%)
Percent -> 0.00034%
PPM 3.4
Process Sigma Level 6.0
Enter DPMO, compute process sigma level
DPMO -> 3.4
Process Sigma Level 6.0
Parts per Million Calculator
NO 1.5 SIGMA SHIFT IN THESE CALCULATIONS
Enter process sigma level, compute PPM
Process Sigma Level -> 6
PPM 0.0
Percent 0.00000%
Enter percent, compute PPM and process sigma level
Percent -> 1.00%
PPM 10000
Process Sigma Level -> 2.326
Enter DPMO, compute process sigma level
Process Sigma Level -> 4.5
DPMO 3.4
Sigma Level (no shift) Calculator
Step DPMO DPMO/1,000,000
1-(DPMO/1,000,000)
1 5,000 0.005
0.995
2 15,000 0.015
0.985
3 1,000 0.001
0.999
4 50 0.00005
0.99995
RTY= 0.99472
Rolled Throughput Yield Calculator
This template calculates the DPMO using the number of defects.
Total number of units: 2500
Number of defects: 4
Opportunities for Error in one unit: 20
DPMO = 80
Not sure of what goes into the units?
The Data Processing Dept supervisor wants to calculate the DPMO of data entry errors in her dept.
A total of 2,500 forms were processed that day, and the supervisor finds 4 fields with error.
There are 20 entry fields on each data entry form.
For this scenario:
Total number of units = 2,500
Number of defects = 4
Opportunities for error in one unit = 20
DPMO Calculator
Conversion Calculator
Defects Per
Million
Opportunities
Sigma Level
(With 1.5
Sigma
Shift)*
Cpk (Sigma
Level / 3) With
1.5 Sigma Shift*
933,200 0.000 0.000
915,450 0.125 0.042
894,400 0.250 0.083
869,700 0.375 0.125
841,300 0.500 0.167
809,200 0.625 0.208
773,400 0.750 0.250
734,050 0.875 0.292
691,500 1.000 0.333
645,650 1.125 0.375
598,700 1.250 0.417
549,750 1.375 0.458
500,000 1.500 0.500
450,250 1.625 0.542
401,300 1.750 0.583
354,350 1.875 0.625
308,500 2.000 0.667
265,950 2.125 0.708
226,600 2.250 0.750
190,800 2.375 0.792
158,700 2.500 0.833
130,300 2.625 0.875
105,600 2.750 0.917
84,550 2.875 0.958
66,800 3.000 1.000
52,100 3.125 1.042
40,100 3.250 1.083
30,400 3.375 1.125
22,700 3.500 1.167
16,800 3.625 1.208
12,200 3.750 1.250
8,800 3.875 1.292
6,200 4.000 1.333
4,350 4.125 1.375
3,000 4.250 1.417
2,050 4.375 1.458
1,300 4.500 1.500
900 4.625 1.542
600 4.750 1.583
400 4.875 1.625
230 5.000 1.667
180 5.125 1.708
130 5.250 1.750
80 5.375 1.792
30 5.500 1.833
Sigma Conversion Table
23 5.625 1.875
17 5.750 1.917
10 5.875 1.958
3 6.000 2.000
The table assumes a 1.5 sigma shift because
processes tend to exhibit instability of that magnitude
over time. In other words, although statistical tables
indicate that 3.4 defects / million is achieved when
4.5 process standard deviations (Sigma) are between
the mean and the closest specification limit, the
target is raised to 6.0 standard deviations to
accommodate adverse process shifts over time and
still produce only 3.4 defects per million opportunities.
Six Sigma Project Timeline
Project Name:
ID Task Hours Start End Status
1 Define 1 Wk 25-Sep-01 1-Oct-01 Complete
2 Measure 17 Wks 2-Oct-01 25-Jan-02 Working
4 Project Direction Meeting 1 Hrs 22-Jan-02 22-Jan-02
5 Assign Roles 5 Min 22-Jan-02 22-Jan-02
6 Review Status 10 Min 22-Jan-02 22-Jan-02
7 Review Schedule 5 Min 22-Jan-02 22-Jan-02
8 Project Direction Decision 33 Min 22-Jan-02 22-Jan-02
9 Clarify Options 10 Min 22-Jan-02 22-Jan-02
10 ID Decision Maker 2 Min 22-Jan-02 22-Jan-02
11 Vote on Options 2 Min 22-Jan-02 22-Jan-02
12 Dialog A 5 Min 22-Jan-02 22-Jan-02
13 Vote on Options 2 Min 22-Jan-02 22-Jan-02
14 Dialog B 5 Min 22-Jan-02 22-Jan-02
15 Vote on Options 2 Min 22-Jan-02 22-Jan-02
16 Decision Maker Decides 5 Min 22-Jan-02 22-Jan-02
17 Assign Tasks 5 Min 22-Jan-02 22-Jan-02
18 Work Tasks 2 Days 22-Jan-02 24-Jan-02
19 Process Map & Data Meeting 96 Min 24-Jan-02 24-Jan-02
38 Work Tasks 1 Day 24-Jan-02 25-Jan-02
39 Tollgate Review 1 Hrs 25-Jan-02 25-Jan-02
40 Analyze 2 Wks 25-Jan-02 8-Feb-02
41 FMEA Meeting 1 92 Min 25-Jan-02 25-Jan-02
50 Work Tasks 4 Days 25-Jan-02 31-Jan-02
51 FMEA Meeting 2 92 Min 31-Jan-02 31-Jan-02
60 Work Tasks 4 Days 31-Jan-02 6-Feb-02
61 FMEA and Data Analysis Meeting 78 Min 6-Feb-02 6-Feb-02
77 Work Tasks 1 Day 6-Feb-02 7-Feb-02
78 Improvement Direction Meeting 1 Hrs 7-Feb-02 8-Feb-02
91 Tollgate Review 1 Hrs 8-Feb-02 8-Feb-02
92 Improve 3 Wks 8-Feb-02 28-Feb-02
117 Control 4 Wks 28-Feb-02 28-Mar-02
Comments
Page: of
Document No:
Department Revision Date:
Storage Location Supercedes:
Responsible Storage Frequencey:
Responsible MSA
Date By %R&R P/T Disc Index
In-Service
In-Service
In-Service
In-Service
In-Service
In-Service
In-Service
In-Service
Calibration GR&R
Resoluton Bias Linearity
Calibration Procedure
Handling and Storage
Stability Date Notes
Baseline
Gage Control Plan
Gage Information
of
Personnel Information
Reference Information
Gage Type
Gage Name
Gage ID/Serial Number
Maintenance
Spare Parts
Relationship Matrix
9=Strong,
3=Moderate,
1=Weak
Q
u
a
l
i
t
y

o
f

S
e
r
v
i
c
e
S
t
a
f
f
i
n
g

L
e
v
e
l
s
C
a
l
l

V
o
l
u
m
e

C
a
l
l

R
o
u
t
i
n
g
T
r
a
i
n
i
n
g
S
y
s
t
e
m
s

P
r
o
b
l
e
m
s
I
n
f
o
r
m
a
t
i
o
n

S
o
u
r
c
e
s
:

S
p
e
e
d
/
A
v
a
i
l
a
b
i
l
i
t
y
C
a
l
l

B
l
o
c
k
i
n
g
A
v
a
i
l
a
b
i
l
i
t
y

o
f

O
t
h
e
r

D
e
p
t
s
E
x
c
e
p
t
i
o
n

P
r
o
c
e
s
s
i
n
g

R
e
w
o
r
k

R
e
d
u
c
t
i
o
n
E
x
p
e
r
i
e
n
c
e

L
e
v
e
l

o
f

R
e
p
s
D
e
l
i
v
e
r
y

o
f

I
n
f
o
T
e
c
h
n
o
l
o
g
y

L
i
m
i
t
a
t
i
o
n
s
H
o
w

I
m
p
o
r
t
a
n
t
B
a
s
e
l
i
n
e
Metric Target
Service Level
IVR Usage
Call Work
Productivity and
Calls Per Hour
Cost
Risk Exposure
Compliance
POC Resolution
Call Duration and
Hold Time
Call Backs
Call Transferred
Call Blocked
Time in Queue
How Important
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Metric
Target
M
a
n
a
g
e
m
e
n
t
E
x
t
e
r
n
a
l

C
l
i
e
n
t
Rating of
Importance to
Customer
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Process Inputs Total
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 0
11 0
12 0
13 0
14 0
15 0
16 0
17 0
18 0
19 0
20 0
0
Total
000000000000000
Cause & Effect Matrix
Page 54
PFMEA Number:
Process Name:
Process Responsibility:
Prepared By:
Affected Product(s):
PFMEA Key Date:
PFMEA Origination Date:
PFMEA Revision Date:
Core Team Members:
Potential Failure Modes and
Effects Analysis (Information
Sheet)
PFMEA Information Sheet
FMEA
Process or
Product Name:
Prepared by: Page ____ of ____
Responsible: FMEA Date (Orig) ______________ (Rev) _____________
Process Step
Key Process
Input
Potential Failure Mode Potential Failure Effects
S
E
V
Potential Causes
O
C
C
Current Controls
D
E
T
R
P
N
Actions
Recommended
Resp. Actions Taken
S
E
V
O
C
C
D
E
T
R
P
N
What is the
process step
What is the Key
Process Input?
In what ways does the Key
Input go wrong?
What is the impact on the
Key Output Variables
(Customer Requirements) or
internal requirements?
H
o
w

S
e
v
e
r
e

i
s

t
h
e

e
f
f
e
c
t

t
o

t
h
e

c
u
s
o
t
m
e
r
?What causes the Key Input to
go wrong?
H
o
w

o
f
t
e
n

d
o
e
s

c
a
u
s
e

o
r

F
M

o
c
c
u
r
?What are the existing controls and
procedures (inspection and test)
that prevent eith the cause or the
Failure Mode? Should include
an SOP number.
H
o
w

w
e
l
l

c
a
n

y
o
u

d
e
t
e
c
t

c
a
u
s
e

o
r

F
M
?What are the actions
for reducing the
occurrance of the
Cause, or improving
detection? Should
have actions only on
high RPN's or easy
fixes.
Whose
Responsible
for the
recommende
d action?
What are the completed
actions taken with the
recalculated RPN? Be
sure to include
completion month/year

0 0
0 0
0 0
0 0
0

0
0 0
0

0
0

0
0

0
0 0
0 0
0 0
Process / Product
Failure Modes and Effects Analysis
(FMEA)
Page 56
FSeverity
Effect Criteria: Severity of Effect Defined Ranking
Hazardous:
Without Warning
May endanger operator. Failure mode affects safe vehicle operation and / or
involves noncompliance with government regulation. Failure will occur WITHOUT
warning.
10
Hazardous: With
Warning
May endanger operator. Failure mode affects safe vehicle operation and / or
involves noncompliance with government regulation. Failure will occur WITH
warning.
9
Very High
Major disruption to production line. 100% of product may have to be scrapped.
Vehicle / item inoperable, loss of primary function. Customer very dissatisfied.
8
High
Minor disruption to production line. Product may have to be sorted and a portion
(less than 100%) scrapped. Vehicle operable, but at a reduced level of
performance. Customer dissatisfied.
7
Moderate
Minor disruption to production line. A portion (less than 100%) may have to be
scrapped (no sorting). Vehicle / item operable, but some comfort / convenience
item(s) inoperable. Customers experience discomfort.
6
Low
Minor disruption to production line. 100% of product may have to be reworked.
Vehicle / item operable, but some comfort / convenience item(s) operable at
reduced level of performance. Customer experiences some dissatisfaction.
5
Very Low
Minor disruption to production line. The product may have to be sorted and a
portion (less than 100%) reworked. Fit / finish / squeak / rattle item does not
conform. Defect noticed by most customers.
4
Minor
Minor disruption to production line. A portion (less than 100%) of the product may
have to be reworked on-line but out-of-station. Fit / finish / squeak / rattle item
does not conform. Defect noticed by average customers.
3
Very Minor
Minor disruption to production line. A portion (less than 100%) of the product may
have to be reworked on-line but in-station. Fit / finish / squeak / rattle item does
not conform. Defect noticed by discriminating customers.
2
None No effect. 1
Page 57
FOccurance
Probability of Failure Possible Failure Rates Cpk Ranking
Very High: 1 in 2 < 0.33 10
Failure is almost inevitable 1 in 3 0.33 9
High: Generally associated with
processes similar to previous
1 in 8 0.51 8
processes that have often failed 1 in 20 0.67 7
Moderate: Generally associated
with processes similar to
1 in 80 0.83 6
previous processes which have 1 in 400 1.00 5
experienced occasional failures,
but not in major proportions
1 in 2,000 1.17 4
Low: Isolated failures associated
with similar processes
1 in 15,000 1.33 3
Very Low: Only isolated failures
associated with almost identical
processes
1 in 150,000 1.5 2
Remote: Failure is unlikely. No
failures ever associated with
almost identical processes
1 in 1,500,000 1.67 1
Page 58
FDetection
Detection Criteria: Liklihood the existence of a defect will be
detected by test content before product advances
to next or subsequent process
Ranking
Almost Impossible Test content detects < 80 % of failures 10
Very Remote Test content must detect 80 % of failures 9
Remote Test content must detect 82.5 % of failures 8
Very Low Test content must detect 85 % of failures 7
Low Test content must detect 87.5 % of failures 6
Moderate Test content must detect 90 % of failures 5
Moderately High Test content must detect 92.5 % of failures 4
High Test content must detect 95 % of failures 3
Very High Test content must detect 97.5 % of failures 2
Almost Certain Test content must detect 99.5 % of failures 1
Page 59
Core Team: Date (Orig):
Date (Rev):
Process Step Input Output
Process
Spec
(LSL,
USL,
Target)
Cpk /
Date
(Sample
Size)
Measure
ment
System
%R&R or
P/T
Current
Control
Method
(from
FMEA)
Who Where When
Reaction
Plan
Control Plan
Current Control Plan
Prepared by: Page: of
Approved by: Document No:
Location: Approved by: Revision Date:
Area: Approved by: Supercedes:
KPOV KPIV
Measurement
Method
Who
Measures
Sub Process
Sub Process
Step
Specification
Characteristic
Specification/
Requirement
USL LSL
CTQ
Sample Size Frequency
Where
Recorded
SOP Reference
Decision Rule/
Corrective Action
Six Sigma Process Control Plan
Customer
Process Name:
Int/Ext
Prepared by: Page: of
Approved by: Document No:
Location: Approved by: Revision Date:
Area: Approved by: Supercedes:
KPOV KPIV
Measurement
Method
Who
Measures
System Failure Mode Predictor
Predictor Level
USL LSL
CTQ
Sample Size Frequency
Where
Recorded
SOP Reference
Decision Rule/
Corrective Action
Six Sigma Preventative Maintenance Plan
Customer
Process Name:
Int/Ext
Customer Requirement
(Output Variable)
Measurement
Technique
%R&R or P/T
Ratio
Upper
Spec
Limit
Target
Lower
Spec
Limit
Cp Cpk
Sample
Size
Date
Key Process Output Variable
Capability Status Sheet
Actions
Failure Mode and Effects Analysis
(Design FMEA) FMEA Number:
Page of
System/Component: Prepared by:
FMEA Date (Orig.) (Rev.)
Core Team:
ActionsTaken
S
e
v
O
c
c
u
r
D
e
t
e
c
R.
P.
N.
Current Design
Controls Detection
Potential Cause(s)/
Mechanism(s) of
Failure
Design Responsibility:
Action Results
O
c
c
u
r
Current Design
Controls Prevention
Item /
Process
Function
Potential Failure
Mode
Potential Effect(s) of
Failure
S
e
v
D
e
t
e
c
R.
P.
N.
Recommended
Action(s)
Responsibility &
Target Completion
Date
The value in the table is the right tail probability.
Hundredth place for Z-value
Z-Value 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0.0 0.50000 0.49601 0.49202 0.48803 0.48405 0.48006 0.47608 0.47210 0.46812 0.46414
0.1 0.46017 0.45620 0.45224 0.44828 0.44433 0.44038 0.43644 0.43251 0.42858 0.42465
0.2 0.42074 0.41683 0.41294 0.40905 0.40517 0.40129 0.39743 0.39358 0.38974 0.38591
0.3 0.38209 0.37828 0.37448 0.37070 0.36693 0.36317 0.35942 0.35569 0.35197 0.34827
0.4 0.34458 0.34090 0.33724 0.33360 0.32997 0.32636 0.32276 0.31918 0.31561 0.31207
0.5 0.30854 0.30503 0.30153 0.29806 0.29460 0.29116 0.28774 0.28434 0.28096 0.27760
0.6 0.27425 0.27093 0.26763 0.26435 0.26109 0.25785 0.25463 0.25143 0.24825 0.24510
0.7 0.24196 0.23885 0.23576 0.23270 0.22965 0.22663 0.22363 0.22065 0.21770 0.21476
0.8 0.21186 0.20897 0.20611 0.20327 0.20045 0.19766 0.19489 0.19215 0.18943 0.18673
0.9 0.18406 0.18141 0.17879 0.17619 0.17361 0.17106 0.16853 0.16602 0.16354 0.16109
1.0 0.15866 0.15625 0.15386 0.15151 0.14917 0.14686 0.14457 0.14231 0.14007 0.13786
1.1 0.13567 0.13350 0.13136 0.12924 0.12714 0.12507 0.12302 0.12100 0.11900 0.11702
1.2 0.11507 0.11314 0.11123 0.10935 0.10749 0.10565 0.10383 0.10204 0.10027 0.09853
1.3 0.09680 0.09510 0.09342 0.09176 0.09012 0.08851 0.08691 0.08534 0.08379 0.08226
1.4 0.08076 0.07927 0.07780 0.07636 0.07493 0.07353 0.07215 0.07078 0.06944 0.06811
1.5 0.06681 0.06552 0.06426 0.06301 0.06178 0.06057 0.05938 0.05821 0.05705 0.05592
1.6 0.05480 0.05370 0.05262 0.05155 0.05050 0.04947 0.04846 0.04746 0.04648 0.04551
1.7 0.04457 0.04363 0.04272 0.04182 0.04093 0.04006 0.03920 0.03836 0.03754 0.03673
1.8 0.03593 0.03515 0.03438 0.03362 0.03288 0.03216 0.03144 0.03074 0.03005 0.02938
1.9 0.02872 0.02807 0.02743 0.02680 0.02619 0.02559 0.02500 0.02442 0.02385 0.02330
2.0 0.02275 0.02222 0.02169 0.02118 0.02068 0.02018 0.01970 0.01923 0.01876 0.01831
2.1 0.01786 0.01743 0.01700 0.01659 0.01618 0.01578 0.01539 0.01500 0.01463 0.01426
2.2 0.01390 0.01355 0.01321 0.01287 0.01255 0.01222 0.01191 0.01160 0.01130 0.01101
2.3 0.01072 0.01044 0.01017 0.00990 0.00964 0.00939 0.00914 0.00889 0.00866 0.00842
2.4 0.00820 0.00798 0.00776 0.00755 0.00734 0.00714 0.00695 0.00676 0.00657 0.00639
2.5 0.00621 0.00604 0.00587 0.00570 0.00554 0.00539 0.00523 0.00508 0.00494 0.00480
2.6 0.00466 0.00453 0.00440 0.00427 0.00415 0.00402 0.00391 0.00379 0.00368 0.00357
2.7 0.00347 0.00336 0.00326 0.00317 0.00307 0.00298 0.00289 0.00280 0.00272 0.00264
Z

2.8 0.00256 0.00248 0.00240 0.00233 0.00226 0.00219 0.00212 0.00205 0.00199 0.00193
2.9 0.00187 0.00181 0.00175 0.00169 0.00164 0.00159 0.00154 0.00149 0.00144 0.00139
3.0 0.00135 0.00131 0.00126 0.00122 0.00118 0.00114 0.00111 0.00107 0.00104 0.00100
3.1 0.00097 0.00094 0.00090 0.00087 0.00084 0.00082 0.00079 0.00076 0.00074 0.00071
3.2 0.00069 0.00066 0.00064 0.00062 0.00060 0.00058 0.00056 0.00054 0.00052 0.00050
3.3 0.00048 0.00047 0.00045 0.00043 0.00042 0.00040 0.00039 0.00038 0.00036 0.00035
3.4 0.00034 0.00032 0.00031 0.00030 0.00029 0.00028 0.00027 0.00026 0.00025 0.00024
3.5 0.00023 0.00022 0.00022 0.00021 0.00020 0.00019 0.00019 0.00018 0.00017 0.00017
3.6 0.00016 0.00015 0.00015 0.00014 0.00014 0.00013 0.00013 0.00012 0.00012 0.00011
3.7 0.00011 0.00010 0.00010 0.00010 0.00009 0.00009 0.00008 0.00008 0.00008 0.00008
3.8 0.00007 0.00007 0.00007 0.00006 0.00006 0.00006 0.00006 0.00005 0.00005 0.00005
3.9 0.00005 0.00005 0.00004 0.00004 0.00004 0.00004 0.00004 0.00004 0.00003 0.00003
4.0 0.00003 0.00003 0.00003 0.00003 0.00003 0.00003 0.00002 0.00002 0.00002 0.00002