Adhoc measures. - use a structured approach for improvement - roadmap or PI.

DMAIC - objective - Improve existing processes - reactive measure Identify pain areas proactive measure - Management system to be put in place - which is proactive and looks at every single process as an engineering activity Design for Six Sigma (DFSS) - Engineer new processes - prototyping stages, simulation, mock cases - treat the new [processes like a product.

Benefits- out of ordinary performance Major disadvantage - longer payback periods. Vaccine dev focuses on DMADV - define, measure, analyze, design, validate - proactive Research on Quality by design in vaccine development -focus is design a product that does not require a lot of inspection. Metric - Methodology and Mgt system Decisions based on edu, exp, env. Data Driven decision making - last stage of decision making - Japan and Germany, Israel - cows, swamp agriculture Chris Collins - erie county. US Presidential candidates - Six sigma projects 100 to 500 years old. Most of the six sigma tools come from agriculture - industrial revolution - economics - financial mgt WWII - all risk mitigation tools, supply chain logistics and improving processes Cold war - space exploration - virtual env, simulation modelling, reliability engineering Motorola - deliver quality at a fantastic price measure, analyse, improve and control GE - product dev and services - customer opinion Structured approach to transform into specification

Japan - dominos - subway - Japanese housewives concept = cleaning without cleaning - outcome engineering 2 types of data - continuous - height, weight, temp, pressure, diameter, time Discrete data - time, counts and classification - analysis of discrete data Pizza delivery eg: Delivery time - output = Y USL - 30 minutes IQR - inter quartile range mean and Std deviation will determine the probability of failure for S and b Out of 900 pizzas how many will be expected to be late Santas prob of failure = 2.81 * 900 = 25.59 = 29 = 12500 lose for delivering pizzas late Bantas prob of failure = 0.217 * 900 = 2 = Variation affects probability of failure and success - Directly proportional Focus - reduce variation - predictability is the key Y = f(x1, x2...xn) X = input process variables Control or influence the inputs = produce predictable output = desirable output Identifying inputs, critical list, controlling or influencing them and eliminate reduce the probability of failure - rework post inspection has reduced.. Focus on function and input use lean to reduce waste...reduce six sigma to eliminate or reduce variation cost is associated with inputs competency mapping - education, experience, training required, mentoring any engineering methodology involves controlling inputs explore inputs that affect output ensure that inputs are within specifications identify which inputs can be controlled.

key things is finding the critical factors and identifying 3 to 4 factors for improvement. six sigma = establishing measurable parameters graphical tools - histogram, box plots spread of a histogram determines how much variation is there in the process Boxplots: can be used for appraisals and salary mapping - box plot or percentile

Boxplot of Pizza B, Pizza S

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histogram is looked at for frequency distribution based. box plots - used for normally and non normally distributed data. Look at 2 things in a histogram - width/speard of the distribution box plot - Q3 - Q1 = interquartile range Max - Min = range Q2 = median

Individual Value Plot of Pizza B, Pizza S

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blue point = mean box plot = percentile/quartile histogram = freqeuncy define phase = focuses on the Y parameter = output identification - project charter measure - evaluate current performance = Y evaluation - baseline performance analyze = identify critical input measures = Xs - validated root causes Improve = optimization of function of inputs - how do we create process to improve- selected solution control = control plan with focus on sustenance of improved performance Define phase: identify output measures or generate project ideas Complaining customer - VOC - waiting time is the output measure yelling boss - VOB - No one to watch the movie - occupancy percentage which will lead to revenue Reason of poor quality - COPQ identify a process and list measures.

losing money for no reason process - pizza delivery identify output measures delivery time y1 - delivery time y2 - pizza temp y3 - defects y4 - billing defects y5 - delivery cost y6 - accidents/1000 pizza create an index to say which is the most desirable for a certain segment list all parameters - select one parameter keep a green belt project within function Projects not to be for cross function Complete the project in 2 to 4 months for services risk - impact - cost (money) - time Finalize a Project charter Business case - cost saving - if changed change to be communicated and signed off Project scope - boundaries opportunity or Problem statement Goal statement - SMART team selection - should be cross functional - take the buy in Project Plan - schedule, milestones, identify the Critical path SIPOC = Supplier Input Output cost identify all inputs and their suppliers

Scope - Do we control the suppliers Constraints - Min hrs of billing Sub processes - macro processes - mention who owns them Functional deployment map / swim lanes Output for internal and external customers Visually established input/ output process Scope and Constraint identification email is also an input 30000 foot view map Bird eye view map High level process map = sub processes and functions responsible for it Step 1 - generating project ideas - identifying output parameter - not required for mature orgs already having a balanced scorecard Step 2 - SIPOC not required. IAAF competition rules CTQ/CTY Operational definition - get an operational definition in place Time to receive payments late payment percentage weight parameters = cricket ball weight USL and LSL anything that has a metric is continuous Operational definition activity is done for measurement system analysis Measurement - shouldn't be affected by measurement system variation and output data should only be due to measurement system Measurement system analysis: repeatability - appraiser ability to agree with himself/herself - within appraiser

reproducibility - appraisers agree with each other - between appraiser individual and team accuracy. - Appraiser agrees with him/herself or expert or standard - appraisers vs standard repeatability and reproducibility cannot be optional accuracy can be optional AIAG standards - greater than 90% accuracy by lab or standard - reproducibility when standard is not available 70 to 90 % cautiously acceptable - data may be collected, however measurement system needs improvement. less than 70% - unacceptable (y are u measuring) Eg BPO sales QA team listens to the call QA team evaluates with checklist 0 = Good process and charge 1= Bad - rework refer to checklist reproducibility is the toughest job define - identify Y measures - VOC, VOB, COPQ select Y measure for project risk, impact and effort Project charter - Business case Scope, Goal, measure - establish operational definition of output measure develop a data collection plan validate measurement system Study page 83 to 107

28-Apr-12 Recap: Analyze: We may have 35-50 inputs Option 1- Collect data, validate inpouts and identify critical inputs - Time, Cost, not feasible Option 2 Narrow down lentghty list of inputs to potential few -Cross functional expertise, less tgime consumi9ng, cost effective

Identify potential inputs -Qualitative Inpouts 1. Braibnstorming, structures bainstorming (Delphi, Expert, De Bono) 2. Affinity Diagram and Ishikawa Diagram 3. Prioritation Tools - Pareto Plots - Nominal Group Technique, Multi Voting - Process Map 1. Time VA/NVA 2. Risks FMEA

We should now have a list of 10-15 potential inputs subjective, prone to bias there is a need for validation data driven.

Option 1 Collect population data, summarize and compare Time, Cost

Option 2 Collect sample data, summarize, hypothesis test (No need of hypothesis testing is population data is used. Its required when small sample data is used) (You cant compare two sample summaries really)

Is the difference observed in sample summary significant to be considered a difference in population parameter? The difference observed may be due to 1. Chance (Sample Probabaility) 2. True Diffeence -