Seven Steps - Page 1 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 7-Step Process for Continuous Improvement Seven Steps - Page 2 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 prayer clairvoyance copy imitation theft consultation delegation negotiation just waiting deceiving hiding lying passing-the-buck confusing finger pointing transferring random trial-and-error guess accident chance luck systematic gut feel the ins innovation insight invention inspiration intuition instinct other world others real world inner self PROBLEM PDCA 7 Steps Shiba WV Options to Problem Solving Seven Steps - Page 3 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 PDCA and the 7 Steps PDCA7 Steps7 QC Tools PLAN1. Select a theme 2. Collect data 3. Analyze causes Checksheet, graph, histogram, scatter diagram, Pareto diagram, cause-and - effect diagram, flowchart DO4. Plan and implement solution Flowchart CHECK5. Evaluate effects Checksheet, graph, histogram, scatter diagram, Pareto diagram, cause-and-effect diagram ACT6. Standardize 7. Reflect on process Flowchart (provides repetition)(provides process)(provides tools) run chart/control chart Seven Steps - Page 4 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 CAUSE not too challenging ?Be important ?Create sense of urgency ?Be solvable in fairly short timeframe (3-4 months is best) ?Motivate team members ?Foster continuous improvement ?Consider these issues: ?Difficulty of situation ?Sense of achievement to be gained ?Urgency/impact ?Quickness of solution ?Theme should: ?Have challenging goals; not too challenging ?Be important ?Create sense of urgency ?Be solvable in fairly short timeframe (3-4 months is best) ?Motivate team members ?Foster continuous improvement Seven Steps - Page 10 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 Theme Selection Matrix LOW = MEDIUM= HIGH Possible symbols to use: THEME 1 THEME 2 THEME 3 THEME 4 Selection Criteria . Possible Themes Urgency Ease of Data Collection Ease of Potential Implementation Speed of Implementation Benefit to Customer Seven Steps - Page 11 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 Clearly State the Theme ?Have weakness orientation ?Have market-in orientation ?State as a problem, not a solution ?State in terms of results, not a solution ?State as a single problem, not several ?Choose words carefully ?Well-defined ?Proper level of abstraction ?Multi-valued orientation ?Have weakness orientation ?Have market-in orientation ?State as a problem, not a solution ?State in terms of results, not a solution ?State as a single problem, not several ?Choose words carefully ?Well-defined ?Proper level of abstraction ?Multi-valued orientation Seven Steps - Page 12 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 Strengths/Weaknesses Chart STEPSTRENGTHSWEAKNESSES 1 2 3 4 5 6 7 Seven Steps - Page 13 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 Step 1: Theme Selection - Reflection Seven Steps - Page 14 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 Case Study Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 1 Theme Selection 7 Step Case Study Seven Steps - Page 15 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 Step 2: Data Collection & Analysis LEVEL OF EXPERIENCE LEVEL OF THOUGHT 7. REFLECT ON PROCESS 6. STANDARDIZE 5. EVALUATE EFFECTS IMPLEMENT 3. ANALYZE CAUSES 2. COLLECT DATA 4. PLAN SOLUTION AND . 1. SELECT THEME EXPLORE ESSENTIALS FORMULATE PROBLEM SENSE A PROBLEM DATA I DATA IIIDATA II Seven Steps - Page 16 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 Step 2: Data Collection and Analysis ?Define your data collection process ?Data appropriate to process ?Multi-variable data (4Ws) ?Analyze the data ?Stratification (4Ws) ?Graphics ?Focus on deviation ?Draw a logical conclusion ?Based on facts ?Focus on vital few ?Use standard tools ?Define your data collection process ?Data appropriate to process ?Multi-variable data (4Ws) ?Analyze the data ?Stratification (4Ws) ?Graphics ?Focus on deviation ?Draw a logical conclusion ?Based on facts ?Focus on vital few ?Use standard tools Seven Steps - Page 17 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 HISTOGRAM CONTROL CHART PARETO DIAGRAMCHECKSHEET xxx xxxxxxxxxx xx xxxxx xxxxxxxx A B C D E Frequently Used Data Collection Tools GRAPH Seven Steps - Page 18 Reactive Improvement - V2.0 Copyright Center for Quality Management 1994 Checksheet ?A checksheet is a tool for systematically collecting data or tabulating collected data ?Types of information: ?Data collection process (e.g., date, time, collectors name) ?Variables associated with the defects (e.g., product type, machine number, shift) ?Type of defect ?A checksheet is a tool for systematically collecting data or tabu