Continuous Improvement Using ProjX, Part 4

Halden Zimmermann's Latest Blog Post

Halden Zimmermann’s latest blog post

Halden Zimmermann: Best Practice Network Team Creation Phase II: Analyze

Create Process Documents Identify Opportunities

• Begin this phase at the same time as Phase I (i.e, at first benchmarking meeting) and continue with conference calls between meetings; when monthly benchmarking meetings are complete, continue with bi-monthly face-to-face meetings rotated between the member plants with conference calls between meetings.


• CreateProcessMap

What stages comprise the process?

• What are the desired outputs of each stage?


• What inputs to each stage influence the output?


• Create Cause and Effect Matrix


• What are our external and internal customers’ requirements (i.e., what are


• the key attributes of our product)?


• Rank requirements by importance to customer (including customer in


• process is desirable)


• Rank inputs identified on the process map by their effect on customer


• requirements/key attributes


• Create Process FMEA (Failure Modes Effect Analysis)


• Use ranking of inputs in Cause & Effect matrix to determine which stages of process are most critical (e.g., drying)


• For these stages, what are the failure modes of the process? Failure modes are the opposite of the desired outputs.


• What are the potential causes of each failure mode?


• Rank severity, frequency of occurrence and likelihood that the failure mode will not be detected – these three rankings are multiplied to produce a risk priority number (RPNs) for that failure mode. Rankings are achieved by consensus of member plants or averaged across the member plants.


• Rank failure modes by RPN. High RPN represents significant improvement opportunity.


• Introduce concept of control plan but do not complete at this time


• This is the plan to prevent the failure modes from occurring.


• What are the spec limits?


• Is the process capable relative to spec limits?


• What are the measurement systems? Where and when do we measure?


• What is the variation due to the measurement system itself (gauge R&R study)?

What do we do if we are out of spec/control (reaction plan)?

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