Module 11 – Jidoka – 0 defects

1. LeanSigma® Facilitator Training Module 11 – Jidoka – 0 defects

2. Topics Jidoka • Built in Quality – DFSS, DFLS, 3P……………………………………..6 - 7 • Root cause analysis – Ishikawa diagram, 5 Whys, Pareto……8 - 17 • Mistake proofing……………………………………………………………18 - 26

3. Lean Sigma has six steps to optimize processes.

4. This module will focus on Jidoka aspects of the Toyota Production System. Principles of LeanSigma® Just in Time Just Just Just Just Jidoka Jidoka in Jidoka in Jidoka Jidoka in in Time Time Time Time Process Smoothing Process Smoothing Process Smoothing Process Smoothing Without all the elements, the house falls! Jidoka • “Built in” Quality • Root Cause Analysis • Mistake Proofing

5. Jidoka is a mindset that doesn’t allow errors to pass to customers. • Allows processes to automatically detect abnormalities and prevent reoccurrence until corrected. • Improves productivity by eliminating the need for people to supervise. • Empowers employees at all levels to: • Help solve problems • To make decisions that affect them • Be accountable for their work • Improve productivity and quality Zero defects!

6. Jidoka • “Built in” Quality • Root Cause Analysis • Mistake Proofing Lean and Six Sigma have approaches to design new processes. Design for Six Sigma (DFSS), Design for Lean Sigma (DFLS) and the Production Preparation Process (3P) are approaches to build new processes that are efficient from the start rather than fixing existing ones. Because kaizens focus on fixing existing processes, new process design sessions have a different agenda and objectives than kaizens. If you can’t say that a process is followed 80% of the time, it’s best to approach it as a new process design.

7. DFLS sessions focus on customer needs. Contact your Lean leader if you think a new process design session is needed. Steps in DFLS Map the high-level process in a SIPOC Discuss & prioritize the customer needs (VOC and Kano model) Prioritize the process requirements and characteristics Construct the new process Click for IMS notes on DFLS

8. Jidoka • “Built in” Quality • Root Cause Analysis • Mistake Proofing Root cause analysis – understanding problems helps us to solve them. People Machine Method The Y Problem or Condition TheX’s (Causes) Categories Material Measurement Environment Because of it’s shape, this is often called a fishboneor an Ishikawa diagram.

9. People Machine Method The Y Problem or Condition TheX’s (Causes) Categories Material Measurement Environment The “head” of thefishis a problemorcondition. Material Products • The “Y” is a problem or condition: • Late delivery • Query responsiveness late • Customer cancellations • Supplier data is late

10. People Machine Method The Y Problem or Condition The Problem TheX’s (Causes) Categories Material Measurement Environment The “bones” of thefish are causes. “X’s” are those factors that may cause the problem or condition “Y”. Y = f(X1…Xn) Material Products • The “Xs” or potential causes are organized into these categories: • People Material • Machine Measurement • Method Environment

11. Examples What are some common root causes at IMS under each category? Measurement: The client’s definition of DAP differs from IMS’ definition. Key project is not included in PMPs. People: People don’t have the skills. Training doesn’t exist. The people responsible for the work don’t have the authority to make changes. Process: No documented process exist. There are too many manual steps. There are steps that don’t add any value.

12. Examples What are some common root causes at IMS under each category? Materials (Supplies): The supplier’s data was late. The supplier blocked access to some of their data. Equipment: The servers went down. A processing error occurred. Environment: Unions went on strike. A hurricane caused pharmacies to close. The government enforced new data privacy laws.

13. Fishbone diagrams are excellent kaizen tools. Why is the coding incorrect? No – 44% Code doctor data Fix coding errors Coding correct? Bridge data Yes 56% When process mapping, you will often see a decision point that has a “good” path and an exception path. If the percent of exceptions is higher than you would like, use the fishbone diagram to determine the causes. Correcting these causes will become part of your action plan.

14. The Five Whys tool can help you understanding underlying causes. • Sometimes symptoms of the problem disguise themselves as root causes. • A way to separate them is the Five Why’s approach. • It is what it sounds like…keep asking why until the answers are “I don’t care. • The root cause is the most basic explanation of a problem origin. If eliminated, it would prevent recurrence. Why, why, why, why, why?

15. Pareto tool can help you understand the vital few causes that cause 80% of issues. • The 80-20 theory says that 80% of the impact comes from 20% of the causes. • If you can identify the 20% correctly, you’ll be well on your way to fixing 80% of the problems. 80 / 20 15

16. The 80:20 Rule Examples • 20% of the time expended produced 80% of the results • 80% of your phone calls go to 20% of the names on your list • 20% of the streets handle 80% of the traffic • 80% of the meals in a restaurant come from 20% of the menu • 20% of the paper has 80% of the news • 80% of the news is in the first 20% of the article • 20% of the people cause 80% of the problems • 20% of the features of an application are used 80% of the time 16

17. Pareto charts show root causes as bar graphs. The most frequent occurrences are always shown on the left. The line above the bar chart shows the cumulativepercent of occurrences. 80% of the issues originate here 17

18. Jidoka • “Built in” Quality • Root Cause Analysis • Mistake Proofing Mistake-Proofing goes one step further than root cause analysis. Prevent Defects Determine Causes Rank/Sort Defects Identify Defects Mistake Proofing C & E Quality Tools Hypothesis Testing Data Collection Pareto Check Sheet

19. Mistake-proofing (Poka Yoke) Examples Parking garages have low clearance. To insure that cars entering the garage will fit, garages are fitted with a go/no-go gauge at the entrance. Hitting the swinging sign or pipe will not damage the vehicle as much as driving into a concrete beam. This iron turns off automatically when it is left unattended or when it is returned to its holder. • Fueling area of car has three mistake-proofing devices: • filling pipe insert keeps larger, leaded-fuel nozzle from being inserted • gas cap tether does not allow the motorist to drive off without the cap • gas cap is fitted with ratchet to signal proper tightness and prevent over-tightening. Even bathroom sinks have a mistake-proofing device. It is the little hole near the top of the sink that helps prevent overflows. Hand washing and Safety Saw videos

20. Mistake-proofing is especially important in processes with people because we are prone to errors. Forgetfulness Misunderstanding/miscommunication Wrong identification, misread Lack of experience/knowledge Inattention Acting too slowly Absence of/poor standards Not following standards Poor judgment in unusual/emergency situations Willful commission

21. Error Proofing Techniques Eliminate Possibility of Error • Reusable code libraries • Child locks on car doors • Cash register calculates change • Programmed phone numbers • Configuration management of code libraries Delegate Necessary Decisions Prevent Errors Match Tasks to Abilities • Implementation checklists/scripts • Color code cables Error Proofing Facilitate Tasks Distinguish Tasks • Spell checking in a word processor • Thresholds on disk usage / monitoring • Peer reviews & checks Detect Errors Mitigate Errors • Auto-correct feature in word processor • UPS • Resilience X Mitigate Errors Nothing • Customer calls you

22. Not all checks are equally effective. Definition Plusses / Problems

23. Mistake Proofing has different levels of intervention. Process stop: Cannot proceed until issue is addressed Shut Down Control Pull-down box: Only “X” choices available – must select from choices Signal Error message: Notification of incorrect data entry by pop-up text box

24. Mistake Proofing examples are common in our lives. Auto-shut-off on gas pumps Double-sided car keys Auto-flush in public facilities What are your examples?

25. Characteristics of Mistake Proofing Reason for mistake proofing device is clear Never fails Defective items never passed on Low or no cost Made with wisdom & ingenuity Simple, durable and easy to maintain Device idea is transferable to other areas Does not interfere with work Associate trained in proper use of device

26. Mistake Proofing Methodology • Identify Defects Tools: Check Sheet • Describe the defects • Determine the defect rates • Rank/Sort Defects Tools: Data Collection, Pareto • Collect/organize defect rate data • Create Pareto chart • Identify “Main Culprit” on which to focus • Determine Causes Tools: C & E, Quality Tools/Hypothesis Testing, Red Flag • Identify probable causes • Use C & E and 5 Why’s • Prevent Defects Tools: Mistake Proofing device • Use associate ingenuity • Use creativity • List alternative ideas to eliminate/detect the error • Create device & test 4 3 2 1

27. Back to EZ Money…. • Finalize your plans for EZ Money with your teams. • Consider: • Work station layout (5S) • Standard work (every employee should understand their role.) • Piloting with a stop watch