Tool Selection Matrix

Tool Definition When to Use Key Questions to Answer Notes:

4 Quadrant Analysis A tool used to compare multiple improvement ideas Use this tool when you need a quick Do I have a long list of good
against two key variables in order to select the items method to determine the improvement ideas?
that a Kaizen team will immediately begin to work. improvement ideas to be
Usually the ideas are judged against significant impact implemented during the Kaizen run Do I need to determine what a
(to improvement metrics) and timing. week. limited group of resources need to
work on in order to make an
immediate impact?

5 Why's The process of asking "Why" five times in order to Anytime that a problem is first being Do you really understand what the A very simple, but powerful tool.
drive the problem statement down to the root cause studied. root cause of the problem is? Can be used out in the Genba with a
level. flipchart to drive to the correct
When the process was in a steady Is your course of action really going problem statement.
state and some change has occurred to resolve the situation?
for the worse or better.
Why is that a problem?

5-S Enabler for making sure you have the right material at This is a foundational tool. How much time do I spend Will highlight problems with flow
the right time searching for items? and equipment operation.
Should be used in an ongoing basis
Key ingredient for organizing a workplace to enable in all departments. Is everything in its place and a place Improves morale.
flow for everything?
Frees up floor space.
As a building block to any Kaizen or Does the place look neat, clean, and
improvement effort. organized?

What method is in place to sustain

the 5S? Can I readily tell when
there is a problem?

Affinity Diagram The affinity diagram is the product of a team's
brainstorming and consensus activities. This process
groups large amounts of data into logical elements
based on the natural relationships among items.
When you need to identify key ideas Do you need to maximize the Assemble post it notes, craft paper,
for process improvement. creativity of your breakthroughs? etc ahead of time.
When you need to identify patterns Do you need to reduce a long list of Allow people to move ideas into
among seemingly unrelated factors. improvement ideas or potential affinity groups without much debate
problems down to a manageable at first.
level?

Do you need to decide which single

improvement idea may have the
greatest overall impact?

C and E Matrix Matrix that identifies a few key process input When you need to see what effect Do you understand which of your This tool really focuses the efforts of
variables that must be addressed to improve the key various inputs and outputs have on process steps have the biggest the team.
process output variables. Similar to a fishbone ranked customer priorities. impact on your customer?
diagram but in matrix form.

Cellular A manufacturing cell or transactional work cell This is a foundational tool. Can you get to one piece flow? All work cells do not have to be in
Manufacturing comprises a group of equipment or processes, usually an "U" shape. Select a shape that
laid out in the shape of a U, that is dedicated to the Use this tool when trying to Do you need a process that will vary will maximize your resources, but
complete production of a family of parts or services. maximize flow and flexibility while output to match demand? always consider the "U" first.
reducing inventory.

Control Charts Control charts are line graphs that display a dynamic
picture of process behavior. A process variable or
attribute can be measured on some given frequency
and that value is plotted verses time on the line graph.
Use this tool when you need to make Do I have a stable, in control
a realtime process performance process?
visible and you need to react to
issues quickly. Does the associate know when to
make adjustments to the process and
when to contact additional resources
for assistance?
You must select the correct control
chart system for the type of data
being collected.
Control Charts are still somewhat
reactive in nature so look for the
mistake proofing opportunity.

Corrective Action A collection of quality improvement tools used to
Kaizen reduce readily identifiable variation and or defects
resulting in a sustained stable process.
When there is a great deal of
variation or defects within a process
either transactional or manufacturing
but the root cause is known with
relative certainty.
Have you completed a Cause and Eliminates easier to see quality
Effect Diagram? issues and prepares the way for other
tools such as standard work or a
Does your control chart demonstrate DMAIC project.
how you have changed your noises
to constants?

What does the Pareto show is the

root cause of the 80%?

How are you measuring

sustainability?

Daily Management Management process and tools which drive To manage daily process through
improvement in Value Stream KPIs at the Genba. conversion of batch to lean
manufacturing, and beyond
Examples include production control boards, conversion to make continuous
communication boards, KPI's and daily "Green Area" incremental improvement. If a
meetings. process area lacks sound daily
management then most improvement
activities will only be marginally
realized.
Do we understand how to manage \
the factory floor on a daily basis?
Are we having difficulty with OTD,
Past Due, quality, efficiency etc.?
Do the Associates at the cell know
what they need to produce today and
in what sequence?

Solution Need/ Want A Decision Analysis tool that is used to compare
Comparison several solutions to understand which one is the most
balanced. It is rooted in understanding what are
customer requirements (needs) and what the customer
finds favorable (wants).
When there are several good Do you have multiple good The highest want is valued at a 10
solutions that could be implemented solutions? and then the rest of the wants are
but resources only allow for one scaled proportionally to the highest
option. Have you thoroughly evaluated what want.
is important to the customer?
Needs are considered "Musts."

Page 1 of 4
Tool Selection Matrix
Tool Definition When to Use Key Questions to Answer Notes:

Design For Six A process to ensure designs can be manufactured at When designing or redesigning any Have I completed a DFSS as part of This tool will yield a more robust
Sigma required Sigma levels to meet the customer product or service that demonstrates developing a new product or design and an effective product
expectations and manufacturing capabilities. variability concerns. process? launch with reduced engineering
changes post product launch.

Design of DOE is the purposeful changing of Inputs to a process As part of new product/process Have you first done an MSA / Gage A DOE is mathematical model that
Experiments to observe the corresponding changes in the Outputs development R&R? describes the relationship between
the inputs and outputs of a process.
To tackle an on-going quality Is standard work in place? It generally takes someone with
problem that has an unknown root extensive training to complete and
cause. Do you need to first do a corrective analyze properly such as a Six
action kaizen to reduce the number Sigma Green Belt.
of inputs?

DMAIC A variation reduction methodology used primarily for
the reduction of variation in complex processes.
DMAIC stands for define, measure, analyze, improve
and control.
To understand and reduce the
variation of a complex process. This
variation may be leading to a wide
variety of issues such as, defects,
over usage of raw materials or
leadtime issues.
Have we done a corrective action
kaizen first?
Do we have GB/BB resources
available?
Have we tried other Lean tools first
that may eliminate "background
noise"?
Typically a DMAIC project and can
take up to several months to
complete. Often the Improve phase
can be accomplished utilizing a
Kaizen event.

Fishbone Diagram The Fishbone diagram typically displays major To assist a team to reach a common Have we investigated all aspects of Do not overload categories.
generic categories such as manning, methods, understanding of a problem and its the problem? Establish another category if more
materials, equipment, measurement and mother nature root causes. detail is desired.
that cause an effect, often perceived as a problem. Have you organized the x's into
To expand the team's thinking and affinity groups? This tool is more effective when
consider all potential causes. used in conjunction with other
decision making tools such as the 4
Quadrant Analysis.

FMEA A failure mode effect analysis (FMEA) is a technique When you need to develop and plan Do you understand which process This tool can get a little long.
that allows a cross-functional team to identify possible solutions or change. deficiencies will impact you the Remember to only focus on the high
potential failure modes that may occur as a result of most? RPN's typically something over 200.
design or process deficiencies. When you need to evaluate a quality
system for protection of your Are you certain that you understand
customers. what all of your liabilities are and
where they exist?

Measurement System A methodology for determining if a Measurement Before performing a DOE and after Is standard work in place? You have to develop a confidence in
Analysis (Gage system is capable of measuring a product or process a corrective action kaizen. the ability of your measurement
R&R) Do you need to first do a corrective system to decide between 'good' and
When there is a process/product action event to reduce the number of 'bad' products or services.
with poor quality out of a machine / inputs?
test equipment.
Is the issue really a problem?
When a product or service passes
your test and fails at the customer
(or supplier)

Mistake Proofing Mistake-proofing the process is to change the method When a process has a low First Pass Can we design the process or Use devices or inspection techniques
or equipment to ensure that a particular error cannot Yield. product so that it cannot be that detect errors during the work
happen. incorrectly performed or made? process rather than at the end of the
When a defect occurrence becomes process.
the largest source of waste or Do we frequently blame the
variation. employee for making an error?

When defects create the demand for

excessive inventory or impede the
ability to meet customer demand.

Pareto Diagram A Pareto Diagram is a bar chart arranged in a Pareto Diagrams can be used almost Do you understand what the most You can "stack" Paretos as you build
descending order of importance from left to right. The anytime and for almost any question. significant problem is? to root case.
Pareto Principle states that 80% of issues are created
by only 20% of the potential root causes. By Are you working on the issue that Paretos work really well when using
determining the "Pareto" you can determine the root will yield the largest amount of the "5 Why" technique.
cause to attack first. improvement?

Policy Deployment A process that facilitates the creation of results-
oriented business processes with sustained
improvement that result in sustained competitive
advantage.
The organization is aligned to the same goals and
objectives.
This is a foundational business How are you communicating goals Creates management accountability.
management tool. and objectives to all parts of the Creates direct linkages for all
organization? objectives from top to bottom of the
When you need to drive the strategic organization.
initiatives to point of impact. Does your current Policy
Deployment give you the continuity
When you need total organizational to be successful?
alignment on business priorities.

Potential Problem The potential problem analysis (PPA) is a tool used for Use in situations where an incorrect Have we thought through all the This tool can take as little as 15
Analysis (PPA) minimizing the probability of solution implementation change could have serious impact to possible ways this action plan may minutes or as long as a day
failure by identifying potential problems and possible the business. fail? depending on the complexity of the
countermeasures. It is a simpler version of a FMEA process change and the level of
and can be applied to less complex changes quickly. Use if there is a good deal of anxiety Do I have a contingency plan if the preparation for the tool use.
over process improvements new process does not work as
implementation. planned?

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Tool Selection Matrix
Tool Definition When to Use Key Questions to Answer Notes:

Production A tool used to establish the best design or the best Used to eliminate barriers to flow Is 3P being incorporated into our Proactively remove barriers to flow
Preparation Process process taking quality, flow, and speed into for developing new products or product development system? while building in quality.
3P consideration. processes. Significantly reduces start-up costs.
Have you done a 3P to determine if a
Assists in thinking 'outside the box' and is used during Also used to improve an existing Capital Appropriation is necessary?
a Kaizen week as a substitute for a DFSS project. product or process. Must be used in
the development stages of a new
product or process.

Pull - Kanban A process to transition businesses from the traditional This is a foundational tool. Why is one-piece flow not possible? Can be used anywhere that 1 pc flow
Push System to a Pull System. A Kanban is a signal in does not exist and materials must be
the system that indicates when work is to be done and When one-piece flow is not Are you experiencing Stock-outs or transported to the cell. Eliminates
when it is to end. This allows for minimal inventory possible. poor OTD? running out of inputs while reducing
and no overproduction. carrying costs.
To ensure that materials are Is inventory creating leadtime,
available when needed and in the quality or cash flow issues?
quantities needed.

Quick Changeover Changeovers are situations where one process must be
(SMED) stopped and reconfigured to run a different product or
service. We define the changeover time as the amount
of time between the last good piece (A) of the current
run and the first good piece (B) of the next run.
If your set-up time is longer than How much set-up scrap do we have? Can be done anywhere that a process
your Takt time (customer demand in must be changed over from one
seconds) Is our set-up time within our Takt product to another or a machine
time? must be stopped to load supplies.
If your set-up is internal to the Great productivity booster! The
machine. Are we doing things while the goal is to have the change occur in
machine is off that can be done less than 10 minutes.
If a long changeover time creates a while it is running?
need to build excessive inventory.

SIPOC Map A form of process mapping that separates out the
process into key inputs and outputs and gives a high
level view of key process steps.
Use this mapping technique when
you need to define and control the
scope of your project or event.
Do you need to better describe the Limit the number of process step
process scope of your event? mapped to 5-7. Include the step just
below and beyond the process in
Do I understand the real needs of my order to better define the scope.
customer?

Spaghetti Diagram A spaghetti diagram is a map of the physical flow of This is a special standard work tool How many times does the work or Try to "straighten out" the spaghetti
either the material, people or information in a process. and should be used anytime the flow worker cross paths during one Takt? during your process improvements.
of a process needs to be
documented. How much non value added motion
exists in the process?

Stakeholder Analysis A stakeholder analysis is a matrix that captures how
all key customers, process owners and senior
management is impacted by and feels toward the
potential process change.
Use this tool early in the change Do I know how all the key "players" Use caution in documenting
process to understand key concerns feel about the work that I am "personal" reasons or bias that are
and roadblocks that you may have to attempting to do? true roadblocks, but need to be
the improvement implementation. handled delicately.
Do I know what issues may come up
at the last minute and prevent or
delay success?

Standard Work A process to maximize performance with minimum
waste through the best combination of people and
process. It captures the key elements needed to meet
cost, quality delivery and safety objectives.
Often deployed while implementing cellular flow.
This is a foundational tool.
When there is too much / too little
capacity.
When we need to improve
productivity and or quality.
Every process should have
documented standard work.
Do products and materials flow With Standard Work in place, you
through the operation or cell? are able to see problems much faster
and once you see the problem, you
Are we using Standard Work, do we are able to solve it much faster.
have a set of Standard Work
documents posted? Increases predictability and therefore
control over the outcomes of
Are Standard worksheets posted in processes.
every work place

Total Productive A series of methods, used to ensure that all equipment Always on critical pieces of Is your OEE low? Increased OEE and reduced
Maintenance is always able to perform its required tasks so that the equipment within the site. Do you have key pieces of equipment downtime. Move from
process is never interrupted due to that equipment equipment that you are dependent unplanned to planned downtime.
being down for un-planned repairs. It places much of on?
the responsibility on the actual person running the Do you have equipment down time
process. issues?

Value Stream Value Stream Mapping is a method that visually Use VSM to provide the focus and Where is your future state map? Maps and action plans should be
Mapping shows the product, material and information flows direction to the objectives updated every 6 months.
within a product or service determined by Policy Deployment. What is the status of your VSM
Action Plan?
Use to communicate how
improvements in Lead Time, On- How do you know which
time Delivery, Inventory Reductions, improvements will take you closer to
etc will impact the process. your vision of the future?

Visual Management Visual Management is a powerful tool that uses visual
techniques to communicate information broadly.
Think in terms of can a new person enter into the
process area and understand how it is performing in
less than 2 mins, without any explanation?
Use visual management in almost all Can I perform a 2 min 360 and Examples range from color codes
situations where it is better, faster understand how well the process is files to overhead realtime displays.
and cheaper to communicate directly operating?
to associates.
Is the information that is important
to users obvious?

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