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Storyboard
[Content Set]
[Covering Year]
Solutions. People.
Innovation.
Solutions. People.
Innovation.
DEFINE
PHASE
Solutions. People.
Innovation.
The Business
Discuss the Content Set of the Lean Six Sigma Project
Take Note!
Coming from the Business Description, now you are discussing the pain you are
experiencing. Your goal here is to let the stakeholders understand the pain you would like
to solve. Please discuss the nature of the problem and NOT its impact/benefit, VOC
addressed or other details that will strengthen its business case. It will come later in the
storyboard.
Solutions. People.
Innovation.
Project Impact
Build the reasons/cases why you would like to solve the project. This should answer the
question, WHAT IS THE PROJECTS WORTH?
You may divide this portion into: Monetary and Non-monetary Benefits, Monetary may be
divided to Hard and Soft Savings
Take Note!
This is actually the Projects BUSINESS CASE. This is where you convey to the stakeholders
that your project is worth the time and effort to solve. Remember, Six Sigma is not an
overnight project, and so it is pertinent to know this early that it is worthwhile to look and
study this concern.
Solutions. People.
Innovation.
Solutions. People.
Innovation.
Monetary Savings
INTERNAL or EXTERNAL
Part of the project impact slide that highlights the monetary benefit of the project (if any).
Computation of savings may come from the difference of the cost of the current metric with
the cost of target metric, elimination/reduction of penalties, etc.
Solutions. People.
Innovation.
SIPOC Diagram
Keep your SIPOC diagram macro in scope. This will just describe which process
steps will contribute to your Y. Coming from the whole stream, you may also
specify which process wil or will not influence your Y, this is critical when you start
identifying your Xs. This portion is not limited to SIPOC, if your process has crossfunctionalities or large in scope. You may start with macro flowchart and detail
down your target process for the project.
Suppliers
Bangalore Quality
Team
Fixed Income
Production
Datascope
Fixed Income
data
Coupon reset
Report data
Datascope
FI data
extracted
Process
Input
Output
Customers
Validated
Metric Results
FI Production
Managers
Metric
Calculation
Process
Senior Data
Managers
Manually
created data
from metric
process
Coupon
Report
data
extracted
Metric
Calculated
Metric
Results
published
Quality
Managers
Metric
Results
Validated
Final
metric
Results
produced
Project Charter
Project Title: Improve Productivity Rate of LN Risk OCC Health Project
Project Leader
Name: Jhonie E. Bohulano
BU / Location: Content Solutions Quality /
CIS
Email: jhonie.bohulano@spi-global.com
Sponsor(s):
Mylene Solete
Key Stakeholder(s):
Van Mondido
Problem Statement:
The average monthly productivity of LN Risk
OCC Health project is only at 115.62 records
per hour which is below the target of 144
records per hour. Data obtained from
February to July 2011
Goal Statement:
Improve productivity rate of LN Risk OCC
Health Project from 115.62 to 144 records
per hour by end of November 2011.
Business Case:
Voice of the Customer
Assumptions Made:
Productivity (speed) =
of records
time consumed in producing a record
Insert Project
Charter
Monetary Benefit
Annual Savings of 70,805.60 PHP 1,
Solutions. People.
706.16
USD
Innovation.
Risk to Success:
Sudden increase in volume; Attrition
10
Project Charter
Project Title: Improve Productivity Rate of LN Risk OCC Health Project
In-Scope
LN Risk OCC Health Project
Out-of-Scope:
Other LN Projects
Signatories:
Nicolai Agcaoili
Project Timing:
Define
W1 of Sept 2011 W2 of
Sept 2011
Measure
W3 of Sept 2011 W4 of
Sept 2011
Analyze
W1 of Oct 2011 W4 of Oct
2011
W1 of Nov 2011 W1 of Dec
Improve*
2011
W2 of Dec 2011
Control
Mylene Solete
Van Mondido
Margarita Magno
Insert Project
Charter
Solutions. People.
Innovation.
11
MEASURE
PHASE
Solutions. People.
Innovation.
12
CTQ
Productivity
KPIs
of records
consumed
hours in
producing a
record
Solutions. People.
Innovation.
SAMPLE ACCOMPLISHED
KPI
Data to be
collected
13
Operational Definition of
Y
Speed or productivity
Productivity (speed) =
of records
consumed in producing a record
Start: From the time the operator recorded
the job
End: From the time the operator exited or
closed the transaction for the particular job
Operational Definition
How do you define each underlying data
Record completed image transacted
Form
element to calculate Y
What gages (instrument) were used?
Worksheet in Google
Yes
Solutions. People.
Innovation.
14
Sampling Size
Calculation
Applies only for Data from Sample (typically for Accuracy Projects)
Solutions. People.
Innovation.
15
Solutions. People.
Innovation.
16
Input
Problem: Incorrect
Invoice
Potential Segmentation/Failure Modes
Product Delivery
Date
Client Data
Payment Terms
Process
Manual or automatically
generated
Presence of revisions
Manual or automatically
generated
Staggered or Joint Invoice
Staggered or Lump Sum payment
Corporation or Medium-scale
Check Client
Terms
Solutions. People.
Innovation.
Write
Invoice
Issue
an
Invoic
e
Print
Invoice
Address &
Send Invoice
Record Data
With Sales
17
Step 1: Select
Improvement
Opportunity
List Opportunities
Priorities List
Select Opportunity
Redefine Team
Write Problem/Opportunity
Statement
Summarize Project/Define
Road Map
Management Review
Solutions. People.
Innovation.
Step 2: Analyze
Current
Situation
Define Process to be
Improved
Flowchart the Process
Collect Baseline Data
Identify Performance Gaps
Validate Problem/
Opportunity Statement
Management Review
Step 3: Identify
Root Causes
18
List Opportunities
Source of Opportunity
Manner of Opportunity Listing (Interview, Mail)
Team Lead involved
Usage of template
Management Review
Solutions. People.
Innovation.
Type of presentation
19
CUSTOMER
INVENTORY CLERK
Receives Product
Cash
Provides Cash
Payment
Method
Credit
Card
Accepts Cash
Type of
Payment
Cashier
Assigned
Customer Age
Bracket
Solutions. People.
Innovation.
20
2 days On-boarding
Immediate V&A Training
Receipt of Job
Request Form
HR Onboarding
10
SLA of Approval:
1 day
QUEUE TIME
CYCLE TIME
10
mins
25
Receipt by
Recruitment Mgr.
45
mins
20
mins
Sieve Ratio:78%
15
mins
25
mins
75
mins
78
mins
Conduct after
3 days of hiring
Job Offer
4 FTE Sr RAs
8 FTE RAs
Final
Interview
Oral
Assessment
3 FTE Temps
Sieve Ratio: 67%
3 FTE Leads
Sieve Ratio: 92%
20
mins
40
mins
Total Turn-Around Time = 258
mins
Total Cycle Time
mins
= 173
21
Numerical Data Y
- Continuous
- Attribute
- Count
Solutions. People.
Innovation.
Contextual Data
Representing the background of
each piece of data
A variety of information some
numerical, some textual and some
mixed
22
Target
Time Factor Y
Solutions. People.
Innovation.
23
Solutions. People.
Innovation.
24
Behavior of Y
Again, there is no straightforward template that you can use because diagnosis of Y
depends on the nature of your data and how you would like to attack your Y. Being the
process owner, this is where you will think how you could approach this problem. On what
areas you would like to view your Y?
Minitab
Tool to be Used
Initial Diagnosis of Y
Controllability of Y
Capability of Y
Initial Segmentation of Y
Solutions. People.
Innovation.
ANALYZE
PHASE
Solutions. People.
Innovation.
26
Y = f (x) Thinking
Target Project Y
Solutions. People.
Innovation.
27
Y = f (x) Thinking
Improve Productivity
of
LNN Risk OCC Health
Project
Slowness of
System
Segmented
per Tenure
Segmented
per Operator
The team decided to segment Y into major partitions which may give hints towards
understanding the source of the problem. This forms part of the contextual data collected
previously in the Measure Phase. The team will further drill down on the root cause should
they find any significant influence to Y.
Solutions. People.
Innovation.
28
Identificati
on of
Image
2 secs.
1 sec.
Submissio
n of Data
Keying of
Data
1 sec.
29
X2: Tenure
Findings:
normal
30
X2: Tenure
Ho: 2 10 months = 2 3
months
Ho: 2 10 months 2 3
months
p-value = 0.399
Findings:
At 95% confidence level, there
is no sufficient evidence to
prove that variance of 10
months is not equal to the
variance of 3 months (with
Solutions. People.
Innovation.
reservation)
31
X2: Tenure
Ho: 10 months = 3 months
Ho: 10 months 3
months
p-value = 0.000
Findings:
At 95% confidence level, there
is sufficient evidence to prove
that mean of 10 months is not
equal to the mean of 3
months.
Solutions. People.
Innovation.
32
X3: Operator
Findings:
The mean of Yca, Jiffy, and Frank are significantly different compared
to the other processors. Further investigation shows that the three
processors have only worked on the project last August 2011 (please
see X2: Tenure)
Solutions. People.
Innovation.
33
X3: Operator
Best Business Practice of
Rain
Has in-depth knowledge of project
instructions
Sets self target above from the
standard
Uses short cut keys (such as
alphabet and tab keys) instead of
mouse in navigating the system
Has favorite account(s)
Keen observer as to the different
OCC images and/or loading of
accounts
Has close to excellent typing skills
and accuracy
Process the file in logical entries (no
need to return to the top to modify
previous entries)
Two to three fields process advance
for every record
Hands and working senses are
performing even on a conversation
Has a good and swift judgment as
far as capturing the printed names
are concerned
Solutions. People.
Innovation.
Grac
e
Myra
Nani
Acel
Yca
Jiffy
Frank
34
X3: Operator
Grac
e
Myra
Nani
Acel
Yca
Jiffy
Fran
k
Rain
Gaps
Records should readily be input
in the performance worksheet
Record non billable work
Solutions. People.
Innovation.
35
Connectivity
No defined
process
work flow
Slowness of
the system
used
Producti
vity of
LN-RISK
OCC
Project
Maturity of
the
processors
Tenure
Solutions. People.
Innovation.
36
Summary of Findings
Root Cause
Slowness of System
Operators have
different processes
in completing an
image
Maturity of
operators (3
months)
Solutions. People.
Innovation.
Method of Validation
Findings
Validity
VALID
VALID
Process walkthrough
INVALID
37
IMPROVE
PHASE
Solutions. People.
Innovation.
38
Solution Identification
This will contain mapping of True Root Causes from Analyze Phase to Identified Solutions.
IT IS NECESSARY THAT ALL IDENTIFIED TRUE ROOT CAUSES ARE ADDRESSED.
Otherwise, you may prioritize in case resource is an issue.
You may also include the proof of concept of your identified solution. If it is a process
change, you may show before and after process flow. If it is a change of policy or platform
show the change and rationality for the change.
If it is necessary to prioritize the solution, show tool/s used to prioritized (e.g. Selection
Matrix)
Solutions. People.
Innovation.
39
Solution Identification
Root Cause
Corrective
Action
Implementation
Date
Status
Slowness of
System
Change connection
to Internet
January 2012
Operators have
different processes
in completing an
image
Sharing of Best
Practices of the top
performer
Completed
Done implementing in the night shift.
Will continue to perform the exercise
until processors are confident with
their typing skills.
Processors will
access Typing
Master Online
Solutions. People.
Innovation.
Solutions. People.
Innovation.
41
Solution Implementation
This will contain the WORK BREAKDOWN STRUCTURE of your identified solution/s.
This will clarify how you plan to execute your solution, the timings, and responsibilities
involved.
SUITABLE TOOL TO USE: GANTT CHART
Critical Components:
Resources needed
Timings
Plan vs. Actual (Remember, your GANTT Chart is also your monitoring tool so
your solutions will be completed in time)
Solutions. People.
Innovation.
42
Solution Implementation
SOLUTION IMPLEMENTATION EXAMPLE:
Solutions. People.
Innovation.
43
Monetary Benefit
Non-monetary Benefit
Solutions. People.
Innovation.
44
Verification of Solution
Effectiveness
Before
After
Rain
155.30
Myra
131.82
Grace
126.30
Nani
124.33
#DIV/0!
Acel
114.14
#DIV/0!
Yca
Jiffy
Frank
Average
210.88
187.84
187.69
72.84
143.88
95.39
119.08
99.75
121.43
130.20
181.28
Monetary Savings
AS-IS
2nd month
after
Implementatio
n (JAN 2012)
UNIT
Productivity
115.62
144.65
181.28
Records/hour
Volume (month)
50,000
50,000
50,000
Records/month
TAKT
432.45
345.66
275.82
Hours/month
130
130
130
Hours/month
3.33
2. 66
2.12
9,000
9,000
9,000
PHP/month
29,938.92
23,930.44
19,094.98
PHP/month
359,267.10
287,165.28
229,139.79
PHP/year
72,101.79
130,127.31
PHP/year
Hours in a
month*
FTE
Monthly rate
Cost per
month**
Cost per year
Savings per year
FTE
Savings per
@41.5 PHP vs
1,737.39
3,135.59 USD/year
Besides
the
savings indicated
*
Used
6.5
productive
hours
@20
days
in
a
month
year ($)
1 USD
** Realized savings for two months is 16,852.42 PHP herein, the projects substantiality
transcends to the fact that this is
a critical SLA for clients which may
result to client pull out for 6
Solutions. People.
consecutive months of not hitting47
Innovation.
Hello
Hello everyone,
everyone,
First
First of
of all,
all, let
let me
me say
say these
these are
are fantastic
fantastic results!
results!
Please
Please extend
extend my
my sincerest
sincerest appreciation
appreciation to
to everyone
everyone
in
in the
the team.
team.
II had
had to
to wait
wait until
until all
all the
the details
details are
are in
in before
before
sending
sending this
this note.
note. As
As we
we have
have originally
originally stated,
stated, itit is
is
essential
essential for
for the
the team
team to
to gain
gain the
the appropriate
appropriate
amount
amount of
of exposure
exposure in
in order
order for
for the
the right
right targets
targets to
to
be
be met.
met. Obviously,
Obviously, there
there is
is still
still work
work to
to be
be done
done on
on
how
how to
to factor
factor in
in multiple
multiple projects
projects and
and its
its effect
effect on
on an
an
individuals
individuals output
output towards
towards establishing
establishing realistic
realistic
targets
targets for
for cross-utilized
cross-utilized resources.
resources. This
This does
does not
not
however
however diminish
diminish the
the outstanding
outstanding work
work done
done
here.
here. We
We are
are very
very glad
glad that
that the
the team
team responded
responded
positively
positively and
and not
not only
only met
met but
but exceeded
exceeded all
all
expectations.
expectations.
Thanks
Thanks also
also to
to Sherwin,
Sherwin, Sonny
Sonny and
and Jhonie,
Jhonie, for
for the
the
patience,
patience, dedication
dedication and
and focus
focus you
you all
all have
have shown.
shown.
This
This is
is aa great
great first
first effort.
effort. Lets
Lets make
make sure
sure the
the team
team
continues
continues this
this path
path of
of on-going
on-going improvement.
improvement.
Have
Have aa great
great day!
day!
Van
Van Mondido
Mondido
Manager,
Manager, CIS
CIS
Solutions. People.
Innovation.
48
CONTROL
PHASE
Solutions. People.
Innovation.
49
Standardization Plan
This will contain how you plan to formally effect the change to your target process.
What to
Standardize?
Who Will
Standardize?
Where to
Standardize?
When to
Standardize?
December 9, 2011
How to
Standardize?
Solutions. People.
Innovation.
50
Metrics to Audit
Activities
Metrics
Management
Description
Create a control chart for
continuous monitoring to provide
clear indication of when
productivity for OCC Health project
has or has not changed.
Date
January 2012
Every Quarter
starting Q1 51
Project Advancement
PROJECT ADVANCEMENT EXAMPLE:
The productivity performance starting February 2012 and the result of
implementing the new connection via internet will be closely monitored
to see if there will be significant improvement on the productivity of
OCC Health Project.
In addition, Behavioral Study may be implemented on other projects
suffering from inconsistent performance of each operator.
Take Note!
All action items that have yet to be completed/started will be indicated here. Continuous
monitoring of the performance will be done to ensure that all action items will be
implemented as scheduled. New problems arising on the project that is not related to the
root causes identified previously will be treated as a separate LSS project.
Solutions. People.
Innovation.
52