DELL6SIGMAGBTRAINING7-5

BPILevelIGreenBeltGlobalBPICopyright©2002DellComputerCorporationRevision052802111BPILevelIModule5-ImproveDefineMeasureImproveAnalyzeControlReportBPIModelBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802112ModuleObjectives:ImproveProcessBenchmarkingEvaluatingProcessImprovementIdeasGenerationReductionEvaluationSelectionShould-BeProcessFailureModesEffectsAnalysis(FMEA)Should-BeProcessPilotStudyProjectManagement(ImplementingtheShould-BeProcessBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802113BenchmarkingTheprocessofcontinuouslycomparingandmeasuringanorganizationagainstotherbusinessestolearnstandardsofperformanceexcellenceforproducts,services,orprocessesHeightenawarenessofhowothercompaniesachievestandardsyoumaywishtoemulateShouldbeintegratedintoon-goingbusinessneedsMustbecustomizedinordertoconsiderculturalfactorswithinacompanyBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802114BenchmarkingExamplesCompanyIssuePartnerResultsRemingtonRifleCompanySurveysrevealedthatRemington’scustomerswouldprefershinyrifleshellsMaybellineRemingtonlearnedfromMaybelline,makersofshinytubesoflipstick,andwasabletoincorporateitsfindingstoimprovecustomersatisfactionSouthwestAirlinesSouthwestwasinterestedinreducingaircraftmaintenanceandturnaroundtimeIndy500pitcrewsSouthwestusedsomeofthecrews’ideastodevelopanactionplanandincorporatethesebestpracticesintoitsownorganizationBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802115ChoosingtheRightFormofBenchmarkingTypeDefinitionExamplesAdvantagesDisadvantagesInternalSimilaractivitieswithinDell,butindifferentlocations,units,countries…Assemblyofmotherboardtoplatform.•Datashouldbeeasytocollect•Goodresultsfordiversifiedcompany•Limitedfocus•InternalbiasCompetitiveDirectcompetitorssellingtosamecustomerbase•BatteriesSonyPanasonicSanyo•Informationrelevanttobusinessresults•Comparablepractices/technologies•Datacollectiondifficulties•Ethicalissues•AntagonisticFunctionalOrganizationsrecognizedashavingworldclassprocessesregardlessofindustry•WarehousingL.L.Bean•ShippingFederalExpress•CycletimeIndypitcrews•Highpotentialfordiscovery•Developmentofprofessionalnetworks•Accesstodatabases•Providesbestoutoftheboxthinking•Transferenceintodifferentenvironment•Time-consumingBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802116MethodologyPlanCollectAnalyzeAdapt•Identifyteam•Determinescope•Identifyboundariesofstudy•Determinecriteria•Determinewhotoresearch•Collectdata•Analyzedata•Summarizeinformationthatmayimpactdesign•DocumentforfuturestudiesBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802117ClassExercise:BenchmarkingQuestions:Who’soutthere?Who’sgood?Who’sbest?Whatdotheydodifferently?Howdotheymakeitwork?Discussion:WhenshouldyouconsiderusingBenchmarking?IsBenchmarkingapplicabletoyourproject?Whyorwhynot?WhatissuesorconcernsdoyouhaveaboutBenchmarking?Ideas&SolutionsBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802118WhatistheSolution?Whileapotentialsolutionmay“jumpout”atyou,itmaynotbethebestoneavailableYouneedtoshiftyourthinkingawayfromconventionalmethodsandmovetothetrulycreativetoshiftyourperspectiveThisapproachtakesyoufromknowingtherootcausetobrainstormingpossiblesolutionsVerifiedRootCausesCreativeToolsPossibleSolutionsBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802119IncrementalVersusBreakthroughImprovementsAreyoutryingtomakeincrementalimprovementstoyourprocessormajorbreakthroughimprovements?IncrementalQuantumorBreakthroughBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802120CreativeToolsforGeneratingSolutionsBrainstormingAssumptionBustingBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802121BrainstormingGenerateasmanyideasasyoucaninashortperiodoftimeCanbestructuredorunstructuredWhataretheadvantagesofstructuredversusunstructuredbrainstorming?*MemoryJoggerpage19liststherulesforbrainstormingBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802122AffinityDiagramOrganizesorgroupsmanyideasorsolutionsintocategoriesProcess:GatherideasorsolutionsTransferverbatimtopost-itnotesGroupnotestofind“affinity”LabelgroupsofnotesGroupclustersifneededDrawdiagramBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802123ClassExercise:AffinityDiagramIdeasorsolutionsarewrittenonnotesMaxtorIBMHDDNotesareclusteredandthemesgeneratedCD/RW1700CPUUSBIt’sokaytohaveclustersof1TherecanbeseverallayersofclusteringCon-nectorCableLCDInverterDisplayFrameBPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802124AssumptionBustingMuchofourthinkingseemstobelimitedbytheunwrittenrulesaroundhowthingswereandaredoneWhataresomefamousassumptionsthatprovedincorrect?BPILevelI-ImproveGlobalBPICopyright©2002DellComputerCorporationRevision052802125AssumptionBustingThesunandplanetsrevolvearou