Six Sigma Green Belt (SSBB)

(Improve)

Six Sigma Methodology

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Define Measure Analyze Improve Control
Opportunities Performance Opportunities Performance Performance

What is How are What is What How do we

important? we doing? wrong? needs to guarantee
be done? performance?

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 Six Sigma Methodology

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Define Measure Analyze Improve Control
Opportunities Performance Opportunities Performance Performance

What How do we
What is How are What is
needs to guarantee
important? we doing? wrong?
be done? performance?
Selection
Matrix
FMEA
Barriers &
Aids Chart

Improve

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Define Measure Analyze Improve Control
Opportunities Performance Opportunities Performance
Performance

• Objectives:
To identify, evaluate and select the right improvement solution, and
to develop a change management approach that assists the
organization in adapting to the changes introduced during the
implementation of the solution.
• Key Topics:
1. Evaluate alternatives. 4. Design for culture.

2. Design remedy. 5. Prove effectiveness.

3. Failure Mode and Effect Analysis 6. Implement
FMEA 4

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 Evaluate Alternatives

• The improvement step starts by deciding on the improvement

that will best remove or reduce the effect of the root cause (s)
of the problem.

• All possible improvements are not equally good.

• The project team must consider a range of possible

improvements and agree on the most effective and appropriate
one.

• The team’s first task is to identify a number of possible

alternatives. Brainstorming is often helpful at this point.

Quality Tool: Remedy Selection Matrix

Criterion Remedy 1 Remedy 2 Remedy 3
Remedy Name
Total Cost
Impact on the Problem
Benefit/Cost Relationship
Cultural Impact/ Resistance to
Change
Implementation Time
Uncertainty about
Effectiveness
Health & Safety
Environment
Summery (Rate 1 for best, 2
for next, and so on.)
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Quality Tool: Remedy Selection Matrix

Criterion Remedy 1 Remedy 2 Remedy 3

Remedy Name
Total Cost
Impact on the Problem
Benefit/Cost Relationship
Cultural Impact/ Resistance to
Change
Implementation Time
Uncertainty about
Effectiveness
Health & Safety
Environment
Summery (Rate 1 for best, 2
for next, and so on.)
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Improve

1. 0 2. 0 3. 0 4. 0 5. 0
Define Measure Analyze Improve Control
Opportunities Performance Opportunities Performance
Performance

• Objectives:
To identify, evaluate and select the right improvement solution, and
to develop a change management approach that assists the
organization in adapting to the changes introduced during the
implementation of the solution.
• Key Topics:
1. Evaluate alternatives. 4. Design for culture.

2. Design remedy. 5. Prove effectiveness.

3. Failure Mode and Effect Analysis 6. Implement
FMEA 13

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 Flow Diagram

• A flow diagram is useful when designing a

remedy, to indicate how the remedy will
operate.

• The visual representation helps the team clarify

the proposed solution, identify any gaps or
ambiguities in the design, and explain the
remedy to others.

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Tree Diagram

Use new Design new guides

out-guides
Order & inventory

Design new covers

Use new
medical Order & inventory covers
record covers
Install covers
New medical-
Record tracking Specify system change
process Computer prints Write new program
Out same-day
Appointment slips Test
Install

Write procedure
Medical record Staff Prepare training
inserts same-day
slips and uses them Conduct training
Conduct dry run
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 Quality Tool: Planning Matrix

• A planning matrix assigns each task in a tree

diagram to an individual, group, or department.

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Tree Diagram with Planning Matrix

What Who When

Use new Design new guides

out-guides
Order & inventory

Design new covers

Use new
medical Order & inventory covers
record covers
Install covers
New medical-
Record tracking Specify system change
process Computer printers Write new program
Out same-day
Appointment slips Test
Install

Write procedure
Medical record Staff Prepare training
inserts same-day
slips and uses them Conduct training
Conduct dry run
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 Improve

1. 0 2. 0 3. 0 4. 0 5. 0
Define Measure Analyze Improve Control
Opportunities Performance Opportunities Performance
Performance

• Objectives:
To identify, evaluate and select the right improvement solution, and
to develop a change management approach that assists the
organization in adapting to the changes introduced during the
implementation of the solution.
• Key Topics:
1. Evaluate alternatives. 4. Design for culture.

2. Design remedy. 5. Prove effectiveness.

3. Failure Mode and Effect Analysis 6. Implement
FMEA 20

Quality Tool: Failure Mode and Effects

Analysis FMEA
• The purpose of this tool is:
– Identify the riskiest bad outputs (Y’s) (symptoms) upon
which the project team should focus.
– Prioritize the order in which the project team should
improve the riskiest bad symptoms.
– Documenting the possible causes (theories) (process
inputs) (X’s), which appear to create each bad symptom.

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 Quality Tool: Failure Mode and Effects Analysis

• Examine a prospective design.

• Eliminate the possibility of failure.
• Stop a failure before it reaches people.
• Minimize the consequences of a failure.

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Failure Mode Effects Analysis

Consider the Fire Extinguisher

Sub-systems/components?

Potential Failure Modes?

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 Item
Failure Mode Effects Analysis

Potential Item and Potential

Hose Failure
Modes Function Failure
Mode

Hose Cracks
Cracks

Pinholes
Pinholes

Blockages
Blockages

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Failure Mode Effects Analysis

Potential Potential
Effects of Causes of Controls
Failure Failure
Occurrence

Potential Potential
Detection
Severity

Item and Potential Current

Effect(s) of Cause(s) of RPN
Function Failure Mode Controls
Failure Failure

Hose Cracks Misfiring Exposure to Insulated

excessive heat packaging mat'ls.
10 or cold during 5 Climate controlled 6 300
shipping shipping

Pinholes Low discharge Damage to the No sharp objects

pressure
8 hose during 8 used in hose 4 256
mfg operations

Blockages No discharge Foreign object Incoming

in the hose inspection and
10 6 hose pressure/air 3 180
passage test
25

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 Failure Mode Effects Analysis

Risk
Priority
Number
RPN = Severity x Occurrence x Detection

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Failure Mode Effects Analysis

Calculating the Risk Prioritization Number (RPN)
Responsibility
Occurrence

Potential Potential
Detection
Severity

Item and Potential Current Recommended and Target

Effect(s) of Cause(s) of RPN
Function Failure Mode Controls Action Completion
Failure Failure
Date
Hose Cracks Misfiring Exposure to Insulated Use hose that is Kevin 4/1
excessive heat packaging mat'ls. not temperature
10 or cold during 5 Climate controlled 6 300 sensitive
shipping shipping

Pinholes Low discharge Damage to the No sharp objects Put a protective Kevin 4/15
pressure
8 hose during 8 used in hose 4 256 Kevlar coating on
mfg operations the hose

Blockages No discharge Foreign object Incoming None

in the hose inspection and
10 6 hose pressure/air 3 180
passage test

RPN
Severity of Probability Ability
Failure Of Failure To Detect

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 Failure Mode Effects Analysis
Improving the RPN:
• To Minimize Severity:
– Change the Design
• To Minimize Occurrence
– Change the Design and/or Process
• To Minimize Detection
– Move to Less Operator-Dependant
Verifications/Inspections

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Improve

1. 0 2. 0 3. 0 4. 0 5. 0
Define Measure Analyze Improve Control
Opportunities Performance Opportunities Performance
Performance

• Objectives:
To identify, evaluate and select the right improvement solution, and
to develop a change management approach that assists the
organization in adapting to the changes introduced during the
implementation of the solution.
• Key Topics:
1. Evaluate alternatives. 4. Design for culture.

2. Design remedy. 5. Prove effectiveness.

3. Failure Mode and Effect Analysis 6. Implement
FMEA 29

10
 Design for Culture
• Quality improvement means change. Something many people
resist.
• People resist solutions because of the cultural changes a new
approach can bring.
• Examples
– A new approach requires that people learn new skills and
procedures. this often reduces the perceived value of those who
were expert in the old ways of doing things.
– People are asked to share a work process with individuals they
have not worked with before.
– People are required to change their schedules-when they come
and go and when they ear lunch, for instance.

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Design for Culture (Con.)

• Many people change their behaviors only
grudgingly, unless they see the clear benefit of the
change.
• To plan for resistance, it is helpful to:
– Identify all likely sources of resistance (barriers) and
support (aids).
– Rate the barriers and aids according to their
perceived strengths.
– Identify countermeasures needed to overcome
barriers.
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 New Video Production Procedures-
Barriers & Aids Chart
Barriers
“deadlines
Keeping log
Expense Hinder
Creativity” extra work

Success of
New video
production
tracking

Positive Director freed

Saves on
Customer to concentrate
Overall cost on creative aspects
feedback

Aids

Demonstrate
Saves on speed and
overall cost simplicity as
training outcome
Countermeasures
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Improve

1. 0 2. 0 3. 0 4. 0 5. 0
Define Measure Analyze Improve Control
Opportunities Performance Opportunities Performance
Performance

• Objectives:
To identify, evaluate and select the right improvement solution, and
to develop a change management approach that assists the
organization in adapting to the changes introduced during the
implementation of the solution.
• Key Topics:
1. Evaluate alternatives. 4. Design for culture.

2. Design remedy. 5. Prove effectiveness.

3. Failure Mode and Effect Analysis 6. Implement
FMEA 33

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 Prove Effectiveness

• Before an improvement is finally adopted, it must be proven

effective under operating conditions.
– Pilot test
• To implement the improvement on a limited scale.
– Dry run
• It does not involve delivery to the customer.
– Acceptance test
• Is a highly structured dry run it is conducted strictly by the people
who will ultimately implement the improvement.
– Simulation
• Used when other options are risky or experience. The solution is
tested under conditions very close to operating environment.
Operation personal should be involved.

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Improve

1. 0 2. 0 3. 0 4. 0 5. 0
Define Measure Analyze Improve Control
Opportunities Performance Opportunities Performance
Performance

• Objectives:
To identify, evaluate and select the right improvement solution, and
to develop a change management approach that assists the
organization in adapting to the changes introduced during the
implementation of the solution.
• Key Topics:
1. Evaluate alternatives. 4. Design for culture.

2. Design remedy. 5. Prove effectiveness.

3. Failure Mode and Effect Analysis 6. Implement
FMEA 35

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 Implement

• implementation requires introducing change to the

people. Who will make it work. these people are
represented in the project team.
• Others will need information and preparation.
• Implementing a change in operations should always
include:
– a clear plan.
– A description of the change.
– An explanation indicating why the change is necessary.
– Involvement of those affected in some aspects of the
planning preparation for the change.
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Implement (con.)
• Change may also require:
– Written procedures.
– Training.
– New equipment, materials, and suppliers.
– Changes in staffing.
– Changes in responsibilities for certain positions.
• The more complex the change, the greater the
need for preparation and planning.

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