Mahindra Black Belt Project Template - New

Lean Sigma Project
Dated: ____ / ____ / ________
Build QM competence | Application orientation | Spread QM | Build team culture | Quality a way of life
Define
Business Opportunity
Top Level Y (Big Y) Impact seen at
Operational Business Level
y1
x1.1
y2
x1.2
y3
y4
x1.3
x1.1
x1.2
x1.3
x1.1
x1.2
x1.3
x1.1
x1.2
x1.3
Critical to Quality and Critical to Process

Chart
Critical to
Quality
Voice of
business
Business
issues
Critical
business
requirement
Critical
customer
requirement
Customer
issues
Critical for
processes
Remark
1. Voice of customer and voice of business to be prioritized to those which are related to project objective
2. Use VOB or VOC or both depending on the project objectives
Voice of
customer
Team Charter
Project Title
Business Case
Opportunity Statement
Pain
Impact of pain in Rs. (or soft)
Sigma Level
Metric
Goal statement
Current
Goal /
level
Target
Target date
Project scope
Process under improvement:
Starts with
Ends with
Phase
Define
Start
Project plan
End
Team Selection
Remarks
Champion:
Measure
GB / BB
Analyze
Member
Improve
Member
Control
Member
Milestone Schedule
Phase Activity Activity Description
no
D
D1
D2
Business impact
Team Charter
D3
VOC-CCR-CTQ, VOB-CBR_CTP
D4
D5
D6
D7
D8
D9
SIPOC
TDC
FDC Detailed Process map
Process Walk through / Qualitative analysis
Quick Wins
Quick win Implementation Plan
M1
M2
M3
M4
Cause and effect matrix

List of Input and Inprocess indicators Xs
Operational Definition for each indicator
Data Measurement Plan
Sample should include all factors of variation.
Data Collection
Summary Statistics
Graphical Statistics Box Plot is a must
Histogram or graph is optional.
M6
M7
M8
M9
M10
Planned
start
Actual
Planned
Actual
Sign off by Sign off
start completion Completion Champion by TQMI
Interpretation for stability of process

Stability should be confirmed before next step
Baseline sigma for each Y
Baseline sigma for each Y
Contd
Milestone Schedule (Contd)

Phase Activity Activity Description
no
A1
Use Pareto and stratify ys
A2
Redo Ishikawa diagram
A3
Carry out Process FMEA
A4
Extract Quick wins
A5
Employ Comparative methods to analyse data
A6
Base line performance of xs and set

improvement goal for each x
A7
Fix Improvement goal for each selected x
I1
carryout affinity diagram
I2
Do Solution mapping six thinking hats
I3
Select solutions
I4
Pilot the solution
I5
Validate the improvement
C1
Implementation Plan
C2
Review and release FDP
C3
Redo FMEA-Introduce Mistake proofing
C4
Install Control Charts
C5
Monitor xs
C6
1.Integrate with ISO system
C7
Prepare for project closure and recognition
Planned
start
Actual
Planned
Actual
Sign off by Sign off
start completion Completion Champion by TQMI
SIPOC DIAGRAM
Process Name
Starting point:
End point:
Suppliers
Inputs
Process
Major step 1
Major step 2
Major step 3
Major step 4
Outputs
Customers
Top Down Chart for PROCESS

Project title
Starting point:
End point:
Functional Deployment Chart

Step
Function / Responsibility
Function-1
Function-2
Function-3
Function-4
Function-5
Function-6
Function-8
Current Value Stream Map
=
C/T =
.
=
C/T =
=
C/T =
C/T =
=
C/T =
=
C/T =
=
C/T =
Process Observation
Process Data Collection Form
Kaizen Planning
Phase 1
Evaluation
Phase 2
Planning
&
Preparation
---Weeks
Phase 3
Event
-- Week
Phase 4
Follow-up
On going
Qualitative Analysis
Project Title:
Pilot Project:
Sr. No.
Activity
Customer
Value added
Operational
Value added
Non-value
Added
Qualitative Analysis
Project Title:
Pilot Project:
Sr.
No.
Source
Concerns
/ Issues
Potential
Quick win
opportunity
(solution)
Easy to
implement
Fast to
implement
Cheap to
implement
Functional
deployment
2
3
Brainstormin
g
Process walk
through
Within the
teams
control
Easy
reversible
Implement
(Yes/No)
Quick Wins Implementation Plan
S. No.
Quick wins
Activities
Responsibilities
Person
Start
Date
Target
date of
completion
Results
Actual
date of
completion
Standardization
of completion
Functional Deployment Chart after Quick wins

implementation (if required)
Step
Function-1
Function-2
Function-3
Function-4
Function-5
Function-6
Function-8
Future Value Stream Map
=
C/T =
.
=
C/T =
=
C/T =
C/T =
=
C/T =
=
C/T =
=
C/T =
Quick Win Results
Measure
Ishikawa Diagram (Cause and Effect Diagram)

Major Categories of causes of Problem Statement
Machine
(Generic Category)
Material
(Generic Category)
Environment
(Generic Category)
Cause
Sub-Cause
Problem
Statement
People
(Generic Category)
Method
(Generic Category)
Cause-Effect Matrix
Input/ Process
indicators
Output #1 Output #2 Output #3 Output #4
Output Indicators
Correlation of input to output
Total
Scale: 0=None, 1=Low, 3=Moderate, 9=Strong

Sl. No.
Performance Indicator (Y)
Operational definition
Process / input indicator (X)
Operational definition
Y1
Y2
Y3
Y4
Sl. No.
X1
X2
X3
X4
..
Remarks:
While writing operational definition keep in mind the data to be collected for each Y & X.
..
Data Measurement Plan

Performance
measure (Y)
Operational
definition
Data source
and location
Sample
size
Who will
collect the data
When will
data be
collected
How will
data be
collected
Other data that

should be collected
at the same time
Process /
Input (X)
Operational
definition
Data source
and location
Sample
size
Who will
collect the data
When will
data be
collected
How will
data be
collected
Other data that

should be collected
at the same time
Remarks:
Other data refers to additional information from stratification perspective.
Carryout MSA
as required
Data collection Format (Modify as per

requirements)
Data Summarization (Y)

Use Histogram, Box Plot, Individual chart, as appropriate (paste output of Minitab/ Sigma XL)
Summary Data (use descriptive statistics in Minitab / Sigma XL)

Baseline definition
Fir continuous (Y)

Output indicator
Y1
Average
Standard deviation
Cp
Cpk
Sigma Level
Y2
Y3
Fir discrete (Y)
Output indicator
Y1
No. of units
No. of opportunities per unit
Y2
Y3
No. of defects
DPMO
Sigma Level
Worksheet for Calculating

Sigma Performance continuous data
1. Label the normal curve with the following:

Calculating Sigma Performance
Enter
Xbar
S
USL
LSL
6.7
0.1533 Delete if no USL
6.8 Delete if no LSL
0.65 Sigma
2. Determine Area 1 :
Z1
USL x
= 0.652316
Find Z1
Look up Z1 in Normal Table
Area 1 = 1 Look Up
3. Skip this step if there is no LSL
Determine Area 2 :
Norm Dist (Z1) = Normal Table Look Up for Z1
= 0.742901
Area 1 = 1 Norm Dist (Z1) = 1 (
= 0.257099
Z2
USL x
Find Z2

LSL X
Find Z2
Z2
Total Area = Area 1 + Area 2 = (

Yield
5. Yield = 1 Total Area
6. Process Sigma Comes from

Table Lookup of yield
= N/A
= N/A
Area 2
Area 2 = Look Up
4. Determine Total Area
= N/A
)+(
= 1 Total Area = 1 (
= x 100%
SigmaST = Lookup value in Sigma Table
)
)
= 0.257099
= 0.742901
=74.2901%
= 0.65
Worksheet for Calculating Sigma Performance

Enter
1.
Number of units processed
2.
Total number of defects made

(Include Defects made and Later Fixed)
3.
Number of defect opportunities per unit
4.
Solve for defects per million opportunities
5. Look Up process sigma in abridged sigma

conversion table
N=
D=
O=
Sigma=
500
57
3
38000
3.27
Process Baseline for Lean Projects
Process steps:
Takt Rate or Takt Time:
WIP
Exit Rate
Process Lead Time (PLT)
Process Cycle Efficiency (PCE)
Analyze
Failure Mode & Effects Analysis

Process / product
FMEA Date (Original)
FMEA Team
(Revised)
Black belt / Green belt
Page:
Process
Actions
Process Potential
Potential
Potential
Risk
steps /
Occurren Current Detectio
failure
effects of Severity cause(s)
priority
requirem
ce
controls n
failure
of
failure
number
mode
ents
Text
Text
Text
Number Text
Of
Number Text
Results
Responsi
Recomm bility and
Action
ended
target
taken
action
completi
on date
Number calculatio Text

n
Text
Text
Severity
Risk
Occurren Detectio
priority
ce
n
number
Number Number Number Calculati

on
Pareto Analysis (If Y is discrete data)
Add Pareto Diagram here
Conclusion:
Multi-vari Analysis (If Y is Continuous data)
Add Tree Diagram and Multi-vari Chart here
Conclusion:
Validation of Xs
Validate each of the prioritized X using tools like Comparative

Methods and Correlation. Optimize using DOE as needed.
Conclusion:
Validation of Xs
For lean projects, identify Time Trap/ Constraints. Use Time

Value Map or Takt time charts.
Conclusion:
Summary of Validated Xs
S. No.
Xs identified as important from FMEA / CE Matrix
Validated (Y/N)
1
2
3
4
5
6
7
8
9
10
11
12
Tool Used
Remarks (attach Minitab /

Sigma XL output)
Improve
List Possible Solutions

(Use tools like Brainstorming, lateral thinking, six
thinking hats, etc.)
S. No.
1
Xs validated
Possible solutions
1.1
1.2
1.3
1.4
1.5
2.1
2.2
2.3
2.4
2.5
3.1
3.2
Future Value Stream Map (VSM)
=
C/T =
.
=
C/T =
=
C/T =
C/T =
=
C/T =
=
C/T =
=
C/T =
Projects / Actions out of Future VSM
For Lean Projects, List Possible Solutions

(Use tools like 5S, Set up reduction, Work control systems.)
If you use 5S
No. of red tags put
No. of red tags addressed
State Before and After (show photographs/ pictures)
Standard method/ check list of cleaning, etc.

If you use Set up reduction use the flow chart.

Classify the steps as in series (internal) or parallel (external)
Define how externals were converted to internal
And how internal were made more efficient
Show state of set up time before and after.

If you use Work Control Systems

Follow steps given on page 84 (section 4.4)
Solution selection Matrix (Cause-1)
-SolutionAgent
Sigma impact
Time impact
Cost/ benefit impact
10
Other impacts Evaluation criteria

Importance
Correlation of solution to criteria

9
3
-Total 180
-SolutionAgent
Sigma impact
Time impact
10

Importance

9
3
-Total 180
-SolutionAgent
Sigma impact
Time impact
10

9
3

Importance
-Total 180
Pilot implementation planning

Tasks
Activities
Responsible person
Start Date
Due Date
Status and
Actions
Scope of pilot :
Result (attach sheet from Minitab or Sigma XL)

Output indicator
Time
Y1line:
Average
Standard deviation
Cp
Cpk
Y2
Y3
Sigma Level
DPMO
Action Plan
Failure Mode & Effects Analysis to confirm

any concerns in solution being proposed.
Process / product
FMEA Date (Original)
FMEA Team
(Revised)
Black belt / Green belt
Page:
Process
Actions
Process Potential
Potential
Potential
Risk
steps /
Occurren Current Detectio
failure
effects of Severity cause(s)
priority
requirem
ce
controls n
failure
of failure
number
mode
ents
Text
Text
Text
Number Text
Of
Number Text
Results
Responsi
Recomm bility and
Action
ended
target
taken
action
completi
on date
Number calculatio Text

n
Text
Text
Severity
Risk
Occurren Detectio
priority
ce
n
number
Number Number Number Calculati

on
Control
Full Scale Implementation Plan

Tasks
Activities
Implementation
strategy
Responsible person
Start Date
Due Date
Status and
Actions
Sequential / Phased / Parallel / Flat (Details to be added)
Result (attach sheet from Minitab or Sigma XL)

Output
indicator
Time
line:
Y1
Average
Standard deviation
Cp
Cpk
Y2
Y3
Sigma Level
DPMO
Action Plan

1. Label the normal curve with the following:
Calculating Sigma Performance
Enter
Xbar
S
USL
LSL
6.7
0.1533 Delete if no USL
6.8 Delete if no LSL
0.65 Sigma
2. Determine Area 1 :
Z1
USL x
= 0.652316
Find Z1
Area 1 = 1 Look Up
3. Skip this step if there is no LSL
Determine Area 2 :
= 0.742901
Area 1 = 1 Norm Dist (Z1) = 1 (
= 0.257099
Z2
USL x
Find Z2

LSL X
Find Z2
Z2
Total Area = Area 1 + Area 2 = (

Yield
5. Yield = 1 Total Area
6. Process Sigma Comes from

Table Lookup of yield
= N/A
= N/A
Area 2
Area 2 = Look Up
4. Determine Total Area
= N/A
)+(
= 1 Total Area = 1 (
= x 100%
SigmaST = Lookup value in Sigma Table
)
)
= 0.257099
= 0.742901
=74.2901%
= 0.65
Worksheet for Calculating Sigma

Performance
Enter
1.
Number of units processed
2.
Total number of defects made

(Include Defects made and Later Fixed)
3.
Number of defect opportunities per unit
4.
Solve for defects per million opportunities
5. Look Up process sigma in abridged sigma

conversion table
N=
D=
O=
Sigma=
500
57
3
38000
3.27
Process Performance for Lean Projects

Before
Process steps:
Takt Rate or Takt Time:
WIP
Exit Rate
Process Lead Time

(PLT)
Process Cycle
Efficiency (PCE)
After
Functional Deployment Chart

Step
Function-1
Function-2
Function-3
Function-4
Function-5
Function-6
Function-8
Future Value Stream Map

(at the end of this Project)
=
C/T =
.
=
C/T =
=
C/T =
C/T =
=
C/T =
=
C/T =
=
C/T =
Process Control System

Input Process
outcome indicators
Control limits
Checking item
Frequency
Responsibilit
y
Contingency
action plan
Remarks
To be prepared for all output indicators and prioritized input / process indicators which required monitoring over time.
Mistake Proofing introduced, if any

Add Mistake proofing introduced with picture/ diagram if any
Visual Controls introduced, if any

Add Visual controls introduced with picture/ diagram, if any for
effective tracking of Ys and/ or Xs listed in Process control systems.
Control Chart introduced, if any

Add Chart introduced with picture, if any for effective tracking of Ys
and/ or Xs listed in Process control systems.
Replication Opportunity
Replication
Solution Focus
Pilot
Site
Company-wide
Standardization
Similar process
Team Reflection
What went well ?
What could be better ?
Project Benefit: Initial estimate / COPQ: $0.00

Project Name
Black Belt (Candidate)
Financial Benefits
1st Quarter
2nd Quarter
3rd Quarter
4th Quarter
Total
Direct savings
$0.00
Increased revenues
$0.00
Reduced costs
$0.00
Working capital changes
$0.00
Investment/ loan changes
$0.00
Cost avoidance (???%)
$0.00
Total
$0.00
$0.00
Non-Financial
Benefits
Signature
$0.00
$0.00
$0.00
Conditions Worksheet :
Initial estimate / COPQ: $0.00
Project Name
Financial Benefits
Conditions
Calculation formulas
Approvals
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
5)
6)
Signature
MBB Name
Date
Champion Name
Date
Finance Name
Build QM competence | ApplicationDate
orientation | Spread QM | Build team culture | Quality a way of life
Calculations Worksheet : Initial estimate

COPQ: $0.00
Project Name
Financial Benefits
Approvals
Signature
MBB Name
Date
Champion Name
Date
Finance Name
Date

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Lean Sigma Project

Dated: ____ / ____ / ________

Critical to Quality and Critical to Process

Cause and effect matrix

Interpretation for stability of process

Milestone Schedule (Contd)

Use Pareto and stratify ys

Redo Ishikawa diagram

Carry out Process FMEA

Extract Quick wins

Employ Comparative methods to analyse data

Base line performance of xs and set

Fix Improvement goal for each selected x

carryout affinity diagram

Do Solution mapping six thinking hats

Pilot the solution

Validate the improvement

Review and release FDP

Redo FMEA-Introduce Mistake proofing

Install Control Charts

1.Integrate with ISO system

Prepare for project closure and recognition

Top Down Chart for PROCESS

Functional Deployment Chart

Current Value Stream Map

Process Data Collection Form

Quick Wins Implementation Plan

Functional Deployment Chart after Quick wins

Future Value Stream Map

Quick Win Results

Ishikawa Diagram (Cause and Effect Diagram)

Output #1 Output #2 Output #3 Output #4

Correlation of input to output

Scale: 0=None, 1=Low, 3=Moderate, 9=Strong

Performance Indicator (Y)

Process / input indicator (X)

Data Measurement Plan

Other data that

Other data that

Data collection Format (Modify as per

Data Summarization (Y)

Summary Data (use descriptive statistics in Minitab / Sigma XL)

Fir continuous (Y)

No. of opportunities per unit

Worksheet for Calculating

1. Label the normal curve with the following:

Norm Dist (Z1) = Normal Table Look Up for Z1

Area 1 = 1 Norm Dist (Z1) = 1 (

Worksheet for Calculating

Look up Z2 in Normal Table

Norm Dist (Z2) = Normal Table Look Up for Z2

Total Area = Area 1 + Area 2 = (

5. Yield = 1 Total Area

6. Process Sigma Comes from

SigmaST = Lookup value in Sigma Table

Worksheet for Calculating Sigma Performance

Number of units processed

Total number of defects made

Number of defect opportunities per unit

Solve for defects per million opportunities

5. Look Up process sigma in abridged sigma

Process Baseline for Lean Projects

Failure Mode & Effects Analysis

FMEA Date (Original)

Dated: / / ____