Case Study

Module 6 focuses on the fifth and final principle of Lean, Perfection. This module introduces several tools associated with Lean, including poka-yoke and

5S

. These tools can be applied in both your professional and personal life.

First Assignment 2 pages Organization Amazon Warehouse

Poka-Yoke

Poka-yoke, the Japanese term for error or mistake proofing, is intended to reduce variation or prevent defects (aka errors or mistakes) caused by human interaction with a process.

Submit a one- to two-page paper responding to the following points:

Thinking of your organization, identify and describe as many examples of poka-yoke as possible. For each of these examples, how do they reduce human variation or prevent defects?

In your personal life, identify and describe some examples of poka-yoke that help you from making mistakes. How do they do this?

Separate Assignment 2 pages Organization Amazon Warehouse

5S

5S is a Japanese organizational methodology with five steps that start with the letter “S”. Some organizations have added a sixth step, Safety.

Submit a one- to two-page paper responding to the following points:

Has your organization implemented 5S? If so, what are some examples? How has 5S impacted your organization positively? If not, what suggestions do you have for implementing 5S?

Let’s move to 5S in your personal life. In most of our residences, there are areas that get cluttered including garages, attics, basements, kitchens, closets, etc. Pick one area and for each step of 5S describe the activities you would do.

3rd Assignment 250 Words Organization Amazon Warehouse

Where do you think that might be able to apply 5S in your week environment, or if you have applied it, what was accomplished/learned?

Project_Charter

DELIVERABLE

MODULE 3 – PROJECT CHARTER

Project Title: Black Belt Project Champion Executive Sponsor MBB/Mentor Problem

Statement Business Case Project Goals Project Scope High Level Project Timeline Constraints & Dependencies Project Risks Additional

Information Phase

Start

Finish Identify Value Map the Value Stream Create Flow Establish Pull Seek Perfection Approval/Steering Committee Stakeholders & Advisors Project Team & SME’s Name Organization

Name Organization

Name

Organization

VILLA

NO

VA UNIVERSITY

High Level

Process

Map

DELIVERABLE MODULE 4 – HIGH-LEVEL PROCESS MAP

Please add in extra processes and symbols as needed

SIPOC

s

Process

s

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
			Supplier	Inputs	Outputs		Customer

VILLANOVA UNIVERSITY
Start

Step 1

Step 2

Step 3

Step 4

End

VSM

Supplier Customer
Information Information

DELIVERABLE MODULE 4 – VSM

Value Stream Map

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Copyright 2016 GoLeanSixSigma.com. All Rights Reserved.

min

min

min

min
min
min
min
min
min
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TOTAL

L/T

P/T

%C&A

Cause_Effect_Diagram

Problem

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”

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

– Re-adjusting process parameters, reworking finished products, off spec materials

Defects

– Making anything sooner, faster or in excess of customer requirements

Overproduction

– Waiting for raw materials, maintenance personnel, processes to finish, and instructions

Waiting

– Workers not involved in improvement areas; input or feedback ignored. Changes without consulting workers and employees not challenged

Non Utilized Talent

– Putting products in work-in-progress areas and moving materials due to poor layout

Transportation

(Excess) – Work-in-progress, rework waiting for testing, excessive raw and finished products

Inventory

(Excess) – Moving tools and people to defferent areas, excessing manual material movement

Motion

– Excessive Quality checks, Performing operations not required

Excessive Processing

DELIVERABLE MODULE 6 – WASTE WALK
8 Wastes/Waste Walks
	Defects
	Overproduction
	Waiting
	Non Utilized Talent
	Transportation
	Inventory
	Motion
	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

Supplier

KANBAN CARD
Part Description/Picture if Applicable Part Number Profile

QTY. Lead Time Due Date

Supplier Location Card #

DELIVERABLE MODULE 7 – KANBAN
	KANBAN CARD
	Part Description/Picture if Applicable		Part Number		Profile
	QTY.		Lead Time		Due Date
	Location		Card #
1 OF 2
2 OF 2

Audit_Checklist

, Procedure etc.

Observation

NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

Observation

YES NO

DELIVERABLE MODULE 7 – AUDIT

Audit Checklist

Target Area:

Statement of Audit Objective:

Auditor:

Audit Date:

Audit Technique

Auditable Item,

Observation

Individual Auditor Rating (Circle Rating)

Have all associates been trained?

YES

Is training documentation available?

Is training documentation current?

Are associates wearing proper safety gear?

Are SOP’s available?

Are SOP’s current?

Is quality being measured

Is sampling being conducted in random fashion

Is sampling meeting it’s sample size target?

Are control charts in control

Are control charts current?

Is the process capability index >1.0?

Number of Out of Compliance Observations

Total Observations

Audit Yield

ERROR:#DIV/0!

Corrective Actions Required

Auditor Comments

VILLANOVA UNIVERSITY