Six Sigma at Boston Scientific Tuesday 12 September 2006 Steve Czarniak

1. Six Sigma at Boston ScientificTuesday 12 September 2006Steve Czarniak BSC Six Sigma: ASQ Meeting – 12 September 2006

2. Session Objectives • Describe the Boston Scientific Six Sigma Model • Describe the Boston Scientific Six Sigma Roadmaps • Identify which Minitab graphs to use to assess measurement system performance BSC Six Sigma: ASQ Meeting – 12 September 2006

3. Six Sigma at BSC is... BSC Six Sigma: ASQ Meeting – 12 September 2006

4. Improvement Challenges • Solution Known • Change in Performance • Operational Defect / Variation Reduction • Flow • Design BSC Six Sigma: ASQ Meeting – 12 September 2006

5. BSC Six Sigma Problem Solving Roadmap BSC Six Sigma: ASQ Meeting – 12 September 2006

6. BSC Six Sigma Operational Process Improvement Roadmap Control Process Improvement Process Control x’s Improve Optimize x’s Analyze Identify Key x’s (Inputs) Measure y = f(x) Identify y’s (Outputs) Define Identify Opportunity Yield Time BSC Six Sigma: ASQ Meeting – 12 September 2006

7. DMAIC Improvement Process Define Measure Analyze Improve Control • Evaluate Measurement System • Determine Process Stability • Determine Process Capability • Determine the Improvement Approach • Identify Opportunity • Define Project Goal • Define Process • Establish Boundaries • Determine Customer Requirements • Define Key Y Variables • Develop Measures (y’s) • Identify Potential x’s • Analyze x’s • Identify Key x’s • Determine Stability & Capability of Key x’s • Establish Relationships between y’s & x’s • Establish Targets & Tolerances for Key x’s • Implement Mistake Proofing • Develop, Select & Verify Process Improvements • Control Key x’s • Validate Process • Verify Long Term Capability • Monitor y’s • Finalize the Control System • Finalize Project Charter BSC Six Sigma: ASQ Meeting – 12 September 2006

8. Balloon Scrap Reduction Define: Reduce balloon scrap for major scrap code by 80% Stable! Measure: Length BSC Six Sigma: ASQ Meeting – 12 September 2006

9. Balloon Scrap Reduction Analyze: Designed Experiment Improve / Control: Mistake Proofing – only use preferred adhesive type! 60% scrap reduction! BSC Six Sigma: ASQ Meeting – 12 September 2006

10. Business Process Improvement Roadmap - DMAIC Measure Improve Control What are you trying to accomplish? How will you know the project has been successful? What elements in your process can be leveraged for improvement? What is your improvement? What is your plan to implement and maintain the improvement? Analyze Define Lean and Six Sigma both use the DMAIC roadmap as a common approach for process improvement BSC Six Sigma: ASQ Meeting – 12 September 2006

11. Business Process Improvement BSC Six Sigma: ASQ Meeting – 12 September 2006

12. Price Approval Process – Reduce Time, Increase Consistency Measure Improve Control Defined goal, talked to the customers and started to understand process complexity Collected data on time and logistics for price approvals Developed detailed process maps, identified waste and non-value added steps, identified gaps between ideal and current state Developed target state, piloted tools for standardizing price approvals and automating repetitive tasks Developed control plan, implemented and monitored new process Analyze Define BSC Six Sigma: ASQ Meeting – 12 September 2006

13. Price Approval - Results • 75% reduction in response time to customer • 62% reduction in process steps • 88% reduction in decision steps • Standardized processes: consistency, accuracy • Customer driven solution “With BPI, our main focus was on our Customer and the requirements that they had. Without their feedback and keeping them our main focus, we would have probably come up with a totally different solution for the process of requesting and receipt of approvals” – Team Leader BSC Six Sigma: ASQ Meeting – 12 September 2006

14. Does this product meet spec? Lower Spec Upper Spec A: yes B: no C: maybe D: not sure - phone a friend BSC Six Sigma: ASQ Meeting – 12 September 2006

15. Measurement System Analysis:Gage R&R

16. The Basic Model The total observed variation is equal to the real process variation plus the variation due to the measurement system. BSC Six Sigma: ASQ Meeting – 12 September 2006

17. Effect of Measurement Variation LSL USL Actual process variation - No measurement variation LSL USL Total observed variation - With measurement variation BSC Six Sigma: ASQ Meeting – 12 September 2006

18. Gage R & R • Means of assessing the repeatability and reproducibility of a measurement system. • Evaluates how much total observed variation is due to the measurement device and measurement methods LSL USL ? Measurement Variation vs. Actual Process Variation BSC Six Sigma: ASQ Meeting – 12 September 2006

19. Gage R&R Example:Graphical Output BSC Six Sigma: ASQ Meeting – 12 September 2006

20. Measurement System Terms • Stability • Accuracy • Precision • Resolution • Bias • Reproducibility • Linearity • Discrimination • Repeatability • Calibration BSC Six Sigma: ASQ Meeting – 12 September 2006

21. Gage R&R Example:Graphical Output 4 1 5 2 6 3 At each table, identify ONE graphic that best describes each term. BSC Six Sigma: ASQ Meeting – 12 September 2006

22. Destructive Gage R&R Reference: De Mast, Jeroen; and Trip, Albert (2005). “Gauge R&R Studies for Destructive Measurement”. Journal of Quality Technology 37 (1), pp. 40-49. BSC Six Sigma: ASQ Meeting – 12 September 2006