Villanova LSS Module 4 project deliverables (High level process map, VSM, SIPOC)
Project_Charter
DELIVERABLE MODULE 3 – PROJECT CHARTER
Project Title:
Black Belt Project Champion Executive Sponsor MBB/Mentor
Tina Agustiady Todd Peterson Andy Myers Michael Bell
Problem Statement Business Case
Poor quality of the Nova Point causes thick or thin product resulting in major quality variation in the product due to materials, methods, machinery, measurements, manpower or mother nature. Business Justification consists of reducing thin/thick Issues associated on the manufacturing line and increasing first pass quality (FPQ).
Project Goals Project Scope
? Increase first pass quality from 91% to 99% ? Reduce holds by 10% ? Determine improved process for thick/thin issues while implementing specifications for ingredients ? Determine the waste coming from the product/process ? Create standardized work and train all associates ? Determine proper preventative maintenance for equipment ? Determine possible equipment replacement and/or upgrades
High Level Project Timeline Constraints & Dependencies Project Risks Additional Information
Phase Start Finish Production output must be maintained • If production is slowed too much due to changes it could effect output • If the materials are brought to the line early they will start to melt before production is started
Identify Value 1-Feb 5-Feb
Map the Value Stream 8-Feb 12-Feb
Create Flow 15-Feb 26-Feb
Establish Pull 1-Mar 12-Mar
Seek Perfection 12-Mar ongoing
Approval/Steering Committee Stakeholders & Advisors Project Team & SME’s
Name Organization Name Organization Name Organization
Todd Peterson Nova Todd Peterson Nova Tom Jones Nova
Andy Myers Nova Andy Myers Nova Michelle VanHutson Nova
John George Nova
Nancy Feller Nova
VILLANOVA UNIVERSITY

High Level Process Map
DELIVERABLE MODULE 4 – HIGH-LEVEL PROCESS MAP
Please add in extra processes and symbols as needed
SIPOC
DELIVERABLE MODULE 4 – SIPOC
Introduction and Instructions for SIPOC
SIPOC is an acronym that stands for supplier, input, process, output and customer
A SIPOC is a process mapping variant that for each process step identifies the inputs, the suppliers (internal or external) for those inputs, the outputs and the customers (internal or external) for that output
Using the template below, begin by filling in the “Process” column with the process steps identified in the high-level process map
Then, for each process step identify the inputs, the suppliers (internal or external) for the inputs, the outputs and the customers (internal or external) for the outputs
S.I.P.O.C. Template
Suppliers Inputs Process Outputs Customers
VILLANOVA UNIVERSITY

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Step 1

Step 2

Step 3

Step 4

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VSM
DELIVERABLE MODULE 4 – VSM
Value Stream Map
Supplier Customer
Information Information
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Cause_Effect_Diagram
DELIVERABLE MODULE 5- CAUSE AND EFFECT DIAGRAM
Instructions:
STEP 1 : Define the problem. What is the product, process or service that has failed.
STEP 2 : Starting with ‘Materials’ or any other label, ask: is there anything about materials that
might contribute to the problem. Record it next to one of the arrows under Materials.
STEP 3 : Repeat asking “is there anything about materials that might contribute to the problem”
Problem Record each result next to an arrow.
STEP 4 : Repeat Step 2 & 3 for each successive category.
STEP 5 : Identify the candidates that are the most likely Root Cause
STEP 6 : If further “screening” is necessary, assess the likely Root Causes using the “Impact”
and “Implement” matrix, selecting items marked 1, then 2 . . . 4 as priorities.
Pareto
DELIVERABLE MODULE 5 – PARETO CHART
Categories # of Occurrences
Issue 1
Issue 2
Issue 3
Issue 4
Issue 5
5-Why’s
DELIVERABLE MODULE 5 – 5 WHY’S
5-WHY ANALYSIS SHEET
Note: Continue on separate page if 5-Whys are not enough to determine root cause.
WHY ? #1:

WHY ? #5

WHY ? #2:

WHY ? #4

WHY ? #3

TEMPORARY Date: COUNTERMEASURES

FINAL COUNTERMEASURE Name: – PERMANENT CORRECTIVE ACTION Date:

VERIFICATION: No Recurrence in Three Months? TBD Date: Single-Point Lesson? _________ Date ________ DO THE 5 WHY’S MAKE SENSE WHEN READ BACKWARD?

Waste Walk
DELIVERABLE MODULE 6 – WASTE WALK
8 Wastes/Waste Walks
Defects – Re-adjusting process parameters, reworking finished products, off spec materials Defects
Overproduction – Making anything sooner, faster or in excess of customer requirements Overproduction
Waiting – Waiting for raw materials, maintenance personnel, processes to finish, and instructions Waiting
Non Utilized Talent – Workers not involved in improvement areas; input or feedback ignored. Changes without consulting workers and employees not challenged Non Utilized Talent
Transportation – Putting products in work-in-progress areas and moving materials due to poor layout Transportation
Inventory (Excess) – Work-in-progress, rework waiting for testing, excessive raw and finished products Inventory
Motion (Excess) – Moving tools and people to defferent areas, excessing manual material movement Motion
Excessive Processing – Excessive Quality checks, Performing operations not required Excessive Processing
Waste Type Describe the waste you saw
Root Cause Analysis
Deliverable Module 6 Root Cause Analysis
Root Cause Analysis (Please state your conclusions)
Kanban
DELIVERABLE MODULE 7 – KANBAN
KANBAN CARD
Part Description/Picture if Applicable Part Number Profile
QTY. Lead Time Due Date
Supplier Location Card #
1 OF 2
KANBAN CARD
Part Description/Picture if Applicable Part Number Profile
QTY. Lead Time Due Date
Supplier Location Card #
2 OF 2
Audit_Checklist
DELIVERABLE MODULE 7 – AUDIT
Audit Checklist
Target Area: Statement of Audit Objective: Auditor: Audit Date:
Audit Technique Auditable Item, Observation, Procedure etc. Individual Auditor Rating (Circle Rating)
Observation Have all associates been trained? YES NO
Observation Is training documentation available? YES NO
Observation Is training documentation current? YES NO
Observation Are associates wearing proper safety gear? YES NO
Observation Are SOP’s available? YES NO
Observation Are SOP’s current? YES NO
Observation Is quality being measured YES NO
Observation Is sampling being conducted in random fashion YES NO
Observation Is sampling meeting it’s sample size target? YES NO
Observation Are control charts in control YES NO
Observation Are control charts current? YES NO
Observation Is the process capability index >1.0? YES NO
Number of Out of Compliance Observations
Total Observations
Audit Yield ERROR:#DIV/0!
Corrective Actions Required
Auditor Comments
VILLANOVA UNIVERSITY