Basic Problem Solving (BPS) -

Project Document

Project Title

Process/Product
TQM to achieve our business goals…

Project Leader Sponsor Name

(Mob No.) (Mob No.)
PS Facilitator/s
Project Code
Name
Unit Function

Start Date (Actual) End Date (Actual)

CFT Members

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 AL-BPS Methodology

Charter, Teaming, Pareto, Project

All possible ‘X’s Problem Management, Matrix diagram

Gemba visit, Check sheet, SPC,

Observation
Stratification, Histogram

Analysis Stratification, Pareto, Fishbone diagram,

Scatter diagram, Concentration chart, SPC

Brainstorming, Solution development, Risk & Cost

Action benefit analysis, Pilot implementation

Check Check sheet, Histogram, Pareto, Run charts, Full

scale implementation, SPC

Standardize Check sheet, SPC

Conclude Pareto, Matrix diagram, Finance vetting, Way forward

Few ‘X’s
Acknowledgements, Future projects

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 Project Selection Grid – 2x2 Matrix

Complexity Score Assessment

Rating Rating guidelines

S.No. Complexity Driver Weightage
(1,3,9) 1 3 9

C1 Frequency of the problem 20 3 Rarely Sporadically / Irregular Regularly / Perennial

Multiple processes in
Multiple plants /
C2 Scope at process level 20 3 Single process Single plant / Single
Multiple Locations
Location
Across segment &
Selective models (within
C3 Scope at product level 20 1 Single model across models (as
segment)
applicable)

Semi or Partially
C4 Degree of process mechanization 20 1 Manual Fully mechanized
mechanized
Potential causes known Root causes not
All Root causes identified
based on past experience known, data
C5 Knowledge about root cause 20 3 & validated;
/ gut feel, yet to be collection and
implementation required
validated with data analysis required
Complexity Score 24%

Impact Score Assessment

Rating Rating guidelines

S.No. Impact Driver Weightage
(1,3,9) 1 3 9

Financial savings (or)

I1 Opportunity loss (in case of non 20 3 < 3.0 Lakhs 3 - 10 Lakhs > 10 Lakhs
cost reduction/non-mfg projects)

Direct impact on Internal

Indirect impact on the Direct impact on End
I2 Impact on customer 20 3 Customer; Indirect impact
internal customer customer
on End Customer
Plant function /
Impact on process/ Shop / Department Business / Company
I3 20 3 Corporate function level
business/stakeholder level metrics level metrics
metrics

I4 Gap between target and actual 20 9 Less than 25% Between 25% to 50% Greater than 50%

Across AL / More
Atleast one direct
I5 Horizontal deployment 20 9 No direct opportunity than one direct
opportunity
opportunity
Impact score 60%
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 Step 1 : Problem Identification
Project Charter
Project Project Leader Unit /
Code Name Function
Project Title
Problem
Definition
In Scope

Project Goal Metric Baseline To be Benchmark

calculated
Cost Savings (INR) Intangible
Benefits
Customer Linkage to
Sponsor KRA
Time Lines (Planned) Project Start Project End date
date
Problem Selection Analysis Action

Check Conclude Lead Time

(Days)

Support Required

Approvals
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 Step 1 : Problem Identification
Project Charter
Project Project Leader Unit /
Code Name Function
Project Title
Problem
Definition
In Scope Out of Scope

Project Goal Metric Baseline Target Benchmark

Cost Savings (INR) Intangible

Benefits
Customer Linkage to
Sponsor KRA
Time Lines (Planned) Project Start Project End date
date
Problem Selection Observation Analysis Action

Check Standardize Conclude Lead Time

(Days)

Support Required

Approvals
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 Project CFT – Details

Name (with Initials Time commitment Photo

# Roles & Responsibility Function
& mobile no) required (Stamp size)

1.

2.

3.

4.

5.

6.
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 Gantt Chart
Project Planning – Plan Vs Actuals
Timelines Plan /
Jun W1 Jun W2 Jun W3 Jun W4 Jul W1 Jul W2 Jul W3 Jul W4 Aug W1 Aug W2 Aug W3 Aug W4
/ Phase Actuals

P
Problem
A
P
Observation
A
P
Analysis
A
P
Action
A
P
Check
A
P
Standardize
A
P
Conclude
A

Legend (for Actuals row): Task Completed All cells in Green color
Task initiated but not yet completed All cells in Yellow color
Quality Month’2015
Task not yet initiated All cells in Red color
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 Problem Background & Impact

• Guideline - Pareto / Pie-chart / Monthly trend / Bar chart

• Use Matrix diagram (if required)

Inference :
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 VOC & Defects “as-is” – Photos

• Insert communication from Customer

• Paste the defect photo as received from the Customer

Inference :
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 Step 2 : Observation
Process Flow Diagram

• List Process flow

OP 10 OP 20 OP 30 OP 40 OP 50

Inference :
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Awareness Creation – Initiatives

Communication Mode
# Initiative Frequency Gemba Resp EDC RYG
(Mail/Displays/Speech etc)
Project Metric
1 Trend Monitoring
& sharing with CFT

• Project metric trend graph (paste)

Inference :
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 Data Collection Plan

Type of Data Data Who will Data Method

Inputs / Sample
Formula (Variable / Source Collect Collection of Collecting
Outputs Size
Discrete) & Location the Data? Frequency data

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Gemba Observation (Defects / Abnormalities)

• Use Check Sheet / Data collection format

• Graph / photo

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 CFT Meetings – Record of Discussions

Review / Total no of Total no of

Place / Members Participated Embed
No Date Discussion Members Members
Location (Initials in CAPS) MOM
with Planned Attended

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 Pareto Analysis / Histogram

• Graph / photo

Inference :
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 Step 3 : Analysis
Brainstorming / Idea Generation
Topic:
Date: Venue:
Participants Name:
1. 4.
2. 5.
3. 6.
Ideas:
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
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 Fish Bone Diagram

Man Machine Material

Cause-1 Cause-1
Cause-1
Cause-2 Cause-2
Cause-2
Cause-3 Cause-3
Cause-3
Cause-4 Cause-4
Cause-4
Cause-5 Cause-5
Cause-5
Effect
Cause-1
Cause-1 Cause-1
Cause-2
Cause-2 Cause-2
Cause-3
Cause-3 Cause-3
Cause-4
Cause-4 Cause-4
Cause-5
Cause-5 Cause-5

Method Measurement Environment

Inference :
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 Why-Why Analysis

Why

Why

Why

• [Text]
Why

• [Text]
Why

Inference :
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 Scatter Diagram / Concentration Chart

• Use if applicable

• Use Microsoft-Excel scatter diagram

• For Concentration chart, pictorial representation of

component / part with consolidation of the defects in
areas or zones to be highlighted

Inference :
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 Root Cause/s – Photo/s

• Paste photo of the root cause/s

• Compress photo size to minimize file size

Inference :
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 Tollgate Review (Till Analyze phase)

Phase Key Milestones RYG Remarks (if any)

Charter Finalization & Sign off by Sponsor

Problem
Estimate cost benefit in INR
Identification

Voice of Customer

Gemba Observation
Observation
Data collection plan formulation

CFT Meetings / Discussion as per Plan

Analysis Awareness Creation / Trend monitoring as per Plan

Root Cause Analysis (RCA)

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 Step 4 : Action
Solution Development & Consensus
Topic:
Date: Venue:
Participants Name:
1. 4.
2. 5.
3. 6.
Ideas:
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
Inference :
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 Solution Selection

Difficult to
Cost of Time to
implement (1-
Implementation implement (1-10) Grand
# Solutions (1-10) 1= least time
10) Rank
1= least Total
1= least cost required
difficult

Note: List all Potential Solutions with CFT and then brainstorm for ranking of the factors on a
scale of 1 to 10. Each one should individually rate first, and finalize with the consensus of CFT.

Inference :
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 Risk Analysis
(Change Management actions)
# Risk mitigation Respons- Approval Deadline RYG
Solution Potential risks
. plan -ibility Authority Date Status

4
.

5
.

Inference :
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 Pilot Implementation Plan
(Change Management actions)
Sample Size
Respons- Deadline RYG
# Counter Measure Pilot area with
-ibility Date Status
Frequency

Implementation From date : To date:

Inference :
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 Step 5 : Check for Effectiveness

• Control Chart / Pareto / Histogram (Before Vs After)

Inference :
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 Full scale Implementation – Plan & Status

Sample Size
Plant / Area / Respons- Deadline RYG
# Counter Measure with
Line -ibility Date Status
Frequency

Implementation From date : To date:

Inference :
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 Tollgate Review (Action & Check phase)

Phase Key Milestones RYG Remarks (if any)

Solution Development & Consensus

Solution Selection
Action
Risk Analysis

Pilot Plan

Effectiveness Check

Check Full Scale Implementation

CFT Meetings as per Plan

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Step 6 : Standardization

• Paste Updated SOP / WIS

• Paste Updated Control Plan

• Paste Poke Yoke details (as applicable)

• Paste Automation & Visual Controls details

Inference :
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 Project Metric Trend – Before Vs After

• Use Trend chart, Pareto, Control chart (as applicable) for

continuing Daily management.

• Paste project metric trend graph

Inference :
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 Before Vs After Improvement

• Use as applicable

• Before Vs After photos to be placed side-by-side, differences,

interventions done to be clearly explained

Inference :
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 Sustenance Audit plan

Audit Check Reporting Non-

# Auditee Auditor When? Where?
point conformance to whom?

4
.

5
.

Inference :
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 Step 7 : Conclude
Project Benefits
• Scanned copy of the finance vetted savings sheet to be shown

• Standardized template enclosed

Inference :
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 Horizontal Deployment

# Plant / Area / Zone / Location Responsibility Deadline date Remarks

• Use if applicable

Inference :
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 Voice of customer (VOC) – After

• Paste email copy

Inference :
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 Tools Used (as applicable)

Key Tools Problem Observation Analysis Action Check Standardize Conclude

Project Charter
Gantt Chart
Pareto Analysis
VOC
Gemba Observation
Process Flow diagram
Check Sheet
C & E diagram
Brainstorming
Data Stratification
Histogram
Scatter Diagram
Concentration Chart
Risk Analysis
Cost Benefit Analysis
SOP/WI/Control Plan
Visual Controls
Poka Yoke
Control Charts
VOC Quality Month’2015
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 Acknowledgements

1. Highlight CFT support

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 TQM to achieve our business goals… Journey of Excellence continues …..

Thank You ….

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