Vinod Shanmugham

Run Chart A Run Chart is a line chart that visually displays data over a period of time. It’s also known as a trend or time series chart. Why Run Chart? Run Charts help us to identify patterns that may exist in the data, and trends over time. When to use Run Chart? You should use Run Charts whenever you want to understand how your process has performed over a certain period of time or when you want to see if your changes resulted in sustainable improvements. In a Run Chart we can identify below non-random variations or patterns: Clusters: Cluster is one where we can see a group of data points in a particular area in the Run Chart. We can also identify the clustering by looking at the probability value. If the probability value for Clustering is less than 0.05, we will be having clustering of data in the Run Chart. Mixtures: If the data points frequently crosses the median line, it’s called Mixtures. We can see than when we pool the data points from more than one population. We can also identify the Mixtures by looking at the probability value. If the probability value for Mixtures is less than 0.05, we will be having Mixture of data in the Run Chart. Trends: A trend is defined as a continued drift or float of data. It can be either in the upward direction or downward direction. This is an indication that the process may in near future go unstable. This may cause due to replacement of operators, aspects such as dilapidated tools etc. Trends can be identified by looking at the probability value. If the probability value for Trends is less than 0.05, we will be having Trends in data in the Run Chart. Oscillations: When data swings upwards and downwards, it’s called Oscillations. This gives an warning that the underlying process is not stable. Oscillations can be identified by looking at the probability value. If the probability value for Oscillations is less than 0.05, there will be Oscillations in data in the Run Chart. Comparison of Run Charts Vs. Control Charts: Below are some comparisons between Run Charts and Control Charts: Run Chart: · Run Chart is simple and can be created easily, · Can be quickly analyzed · A person looking at a Run Chart does not require statistical knowledge to read the chart However, a run chart lacks the below advantages which a Control Chart possesses: Control Charts: · A control chart will help us understand whether the process is stable or in control · Is the process in the correct track

What is PFMEA? A Process Failure Mode and Effects Analysis (PFMEA) is a step-by-step approach that identifies process failure modes and the effect of each of those failures. A calculated risk score (Risk Priority Number) is derived for each failure in the process step, based on its Severity, Occurrence and Detectability. Why PFMEA? We do PFMEA primarily: •To prioritize the list of failures based on the calculated risk score •To target the high scoring failures for improvement •To document the current knowledge and proposed actions to be taken to address the risk of failure When do we do FMEA? •Use FMEA whenever an assessment and prioritization of risk is needed •When designing or redesigning a process or product •Before developing a control plan for a modified process •Periodically, to assess process risks and failures Challenge in Severity Assessment: One of the major challenges in Severity Assessment we face while conducting a PFMEA is that the team not agreeing on Severity Rating. Assessing Severity is important part of FMEA. Once the FMEA team identifies the most serious effect of the failure mode, the team then makes the assessment of ranking for Severity. One thing we have to keep in mind is that here we are looking at the severity of the effect of the failure mode and not the severity of the failure mode itself. If the effect is not well defined, that’s where it becomes a challenge or difficulty to assess the severity by reviewing the severity scale criteria. How can this challenge be addressed: For a Process FMEA, what the team should consider is the effect of the failure at Process level as well as at the end-user/customer level. Once the effect is properly articulated, then the severity can easily be arrived at by looking at the severity scale.

As-Is Process map, otherwise called as Current State process map is drawn to understand how the process is presently carried out. It is a pictorial way of depicting all the major activities or tasks performed to deliver the process outcome. As-Is process map helps to visualize the current process and is drawn during the Define and Measure phase of DMAIC project. The following thumb rules can be kept in mind while deciding how much detail should be included in the process map: 1. Not too much and not too less: An ideal As-Is process map should cover below details: a. Inputs that goes into the process to provide the output of the process b. Inputs which are controllable by the business and the ones which business cannot control; including the critical inputs c. Which of the tasks / activities are Value Added (VA) and which are Non Value Added (NVA) including process metrics like Cycle Time, Processing Time and Lead Time d. Different hand-offs in the process e. Highlights opportunities for Elimination, Combining, Rearranging, Standardizing and Simplification with or without automation f. Highlights bottlenecks in the process 2. Opportunity Identification: One could keep on including details in a process map until he thinks that he has drawn a perfect map. But is that what we are looking for? Ideally we should map the process to the level that will help us to identify the opportunities for improvement. 3. Purpose: Before drawing the process map, ask ourselves the question as to why are we drawing the map. Focus on the purpose of what we intend to achieve 4. Notations: Business Process Modelling Notations (BPMN) standards prescribe the symbols and notations we should use while drawing the map. Adhering to BPMN standards will ensure that the map follows a standard and others can correlate and understand easily