1.1 BIBLIOGRAPHIC ENTRY. Sinn, J. (2006). Lean six sigma quality transformation toolkit (LSSQTT) LSSQTT Tool #17 Courseware Content
"Standard Operating Procedures (SOP) For Lean And Six Sigma: Infrastructure For Understanding Process." LSSQT: Part 2. Standardization around
2.1 ABSTRACT/BIG IDEAS. The most important statement in this entire article is : "It is impossible to pursue improvement of any sort without first
having the baseline of standards." The SOP's can always be updated as operators become more experienced with the tasks being performed. The
baseline SOP is very important. How can one improve on the process if they can't remember what has already been tried?
SOP's are Standard Operating Procedures and they are exactly what they say they are. SOP's are a detailed description of the work, how to perform
the work safely and economically, and who is responsible for performing the tasks stated in the SOP. Standardizing the SOP and its documents and
visuals are important to ensure that all operators understand how to interpret the documentation as they move from task to task. A standardization of
the SOP allows the operator to efficiently study the work procedures without having to learn a new format every time he/she moves to a different work
station. The purpose of the SOP is to provide standardized work that will produce high quality products safely and economically.
From my experience, SOP's are the most difficult of Six Sigma documents to maintain. Operators are very busy people. They are expected to hit their
production numbers, keep defects and defectives to a minimum, and do all of this in a safe manner. Operators are always finding ways to increase
throughput. Of course, because of their busy nature, they don't always have time to document new procedures, and therefore, their ideas do not pass
on to the rest of the team.
While working at a small automotive stamping and welding company, I witnessed an operator run a machine, at the suggested hourly rate, that no
one else in the facility was able to reproduce. Numerous different operators tried to operate the machine at rate by following the SOP but it was nearly
impossible. This gentlemen operated the machine at the hourly rate and still had time left over at the end of each hour to briefly clean the area. He
wasn't quite sure exactly what he was doing different to make the hourly rate so we recruited a manager, a technician and a quality tech to observe
his winning formula. We found that this operator was taking 3 less steps for every part that he introduced and removed from the machine. Pallet
placement was marked on the floor in yellow and no pallets were to be outside of their designated boxes. This operator moved each pallet closer to
him by about 6 inches. After we studied other unsuccessful operators we found the solution. The yellow boxes on the floor were moved closer to the
operators, and almost immediately everyone was running rate on this machine. The SOP clearly stated that the pallets are to be placed in their
designated areas, if this gentlemen wouldn't have deviated from the SOP, we would never have found the problem. Its too bad the operator didn't
pass this information on to his supervisor at an earlier time.
3.1 STRENGTHS/WEAKNESSES. Strengths: The article explicitly explains standardization of standard operating procedures and why they are
important to standardize and follow. The article also makes it clear that the SOP's are dynamic and not static, meaning they can be changed, as long
as they are documented appropriately, as operators find safer and more economic ways of doing things.
Weaknesses: I always find examples useful to further implant the ideas into my head. This article could be better if it offered examples of how SOP's
can help improve the process.
4.1 SELF ASSESMENT. I feel the grade deserved on this work should be an A. I have met all of the requirements asked by the instructor with
thoughtful analysis and research.
Angel Estrada, QS-727, Fall 2009 Page 1 of 8 Assign 9, 10/12/09
QS-3600, Spring 2010
1.1 BIBLIOGRAPHIC ENTRY. Munro, Roderick A. (2002).Six Sigma For The Shop Floor A Pocket Guide. Standard Operating Procedures.
Retrieved from http://books.google.com/books
2.1 ABSTRACT/BIG IDEAS. SOP's (Standard Operating Procedures) are known by many different names throughout the industry: work instructions,
level three ISO 9001 documentation, operating guidelines, job aids, standard job practices, and many more. An SOP is just a step by step description
how to do a task. The SOP should give details on how the job should be performed, who does the SOP apply to, what is the specific job, when does
the SOP apply and who is responsible...etc. Operators should be responsible for following SOP's word for word. Deviations from the SOP should be
documented appropriately, if a quality issues appear at a later date, documentation can be produced to explain why the operator deviated from the
SOP. Operators should update SOP's as they notice improvements that can be made to the task. The improvements could be anything from different
inspection techniques, different operating techniques that could increase cycle times and so on. When the operator makes changes to the SOP he
must also take responsibility to see that all SOP documents are updated properly.
3.1 STRENGTHS/WEAKNESSES. The article is explains very well exactly what SOP's are, what data they should contain and how to use the
Weaknesses: Because it is a pocket book guide, the articles don't go into detail of the entire SOP framework.
4.1 SELF ASSESSMENT. I feel the grade deserved on this work should be an A. I have met all of the requirements asked by the instructor with
thoughtful analysis and research.
Angel Estrada, QS-727, Fall 2009 Page 2 of 8 Assign 9, 10/12/09
ONGOING PROCESS CONTROL PLAN
ONGOING PROCESS CONTROL PLAN
Customer: Page 1 of 1
Prototype Pre- Launch Production Key Contact/Phone: Ext 2334 Date(Original): Date(Revision):
Control Plan Number: 19-Feb-10
Part Number/Latest Change Level: Core Team: Team 3 Customer Engineering Approval/Date:
Revision 1 19-Feb-10
Part Name/Description: Supplier/Plant Approval/Date: Customer Quality Approval/Date:
Ford Explorer Rear Floor Pan 19-Feb-10 19-Feb-10
Supplier/Plant: Supplier Code: Other Approval/Date: Other Approval/Date:
PPI 1234 19-Feb-10 19-Feb-10
Part Stamping Machine, Device, Characteristics Special Methods
Process Ford Explorer Rear Jig, Tools. Char. Product/Process Evaluation Measurement Sample Control Reaction Plan
Number Floor Pan For Mfg. No Product Weld Class Specification/Tolerances Technique Size Frequency Method
1 Receiving Receiving Dock 1 Receipt & * Quantity, delivery Visual All Per Lot # Certified vendors, Notify supplier. Isolate
Verification & damage. Purchase orders / material until disposition
Packing slips. is reached. Corrective
2 Move steel coil Warehouse 1 Relocation to FIFO Visual All Per Lot Procedures / Notify Material Handling
Warehouse Work Instructions Supervisor. Initiate
Trained Material a corrective action.
3 Store steel Warehouse 1 Storage FIFO / Storage & Preservation Visual All Per Lot Crane operator Notify supervisor. Initiate
Procedure verifies goods against corrective action.
storage floor plan.
4 Mount steel T2 Coil Line 1 Relocation to FIFO Visual All Per Lot Procedures / Notify Material Handling
Machine SOP Supervisor. Initiate
Trained Material a corrective action.
5&6 Insert Die into T2 Press T2 Press 1 Length 82.4 in +/- .1 in Tape measure 1 piece Per 50 Job control plan Stop production. Inform
Inspection Pieces Work order record Supervisor. Sort back
through till pts. conform.
2 Width 72 in +/- .1 in " " " " "
7&8 Packaging & T2 Press 1 Amount per container Must have correct Photo eye 8 Per Job Contol Plan Re-Count &
Labeling amount of parts verification Rack SOP Re-Pack Parts.
Work order record
2 Label information Hand written label must have " " " " Change label to
the proper part # reflect the proper
and quantity information.
9 Move stamping to weld Robot weld cell. 1 Relocation to FOFI Visual All Per Lot Procedures / W. Inst. Notify Material Handling
department. Robot Cell Trained Material Supervisor. Iniciate
Handlers a corrective action.
10 Mate rear floor pan with Robot weld cell. 1 Weld FIFO Visual All Per Lot SOP Notify supervisor. Initiate
center floor pan at robot Trained Material corrective action.
weld cell. Handlers
11 Package and label parts. Robot Weld Cell. 1 Overall condition of As per Work Instruction Check Sheets, JCPs, 8 Robot Weld Cell Isolate order.
parts, labels, cartons, Blue Prints. Per Rack check sheet. Hold for 100%
amounts etc. inspection.
2 Part Verification Parts in rack must match Visual, Work order " " "
Work order / Label Label
12 Move parts to finished Warehouse 1 Part delivered to On-time and free of Barcode Scan In 100% All SOP Corrective action.
inventory. the customer damage Orders Trained Material Notify customer.
13 Ship parts to customer. Shipping Dock 1 Part delivered to On-time and free of Barcode Scan Out 100% All Shipping Log Corrective action.
the customer damage Orders On time delivery Notify customer.
QS-3600, Spring 2010
1.1 BIBLIOGRAPHIC ENTRY. Sinn, J. (2007).Lean six sigma quality transformation toolkit (LSSQTT) LSSQTT CA 5.4
Courseware content "OPCP"
2.1 ABSTRACT. OPCP (Ongoing Process Control Plan). The OPCP is generally driven by customer requests and is
composed of detailed information from engineering, quality, customer requests, and other sources. Part of the OPCP is the
standard operating procedures for each major process operation. The OPCP is designed to detail the following key
1. Key Methods and Techniques used in the Process : Process name, tools used, process parameters and product
2. Step by Step Procedure for Completing Process: Tracking from the time the material enters the plant to the time the
finished product leaves the facility
3. Identify Customer Expectations and Specifications: Evaluation methods, sample and inspection frequencies, and
analysis and corrective action methods.
4. Additional Internal Engineering Quality Information: Drawing and sketches of the parts, product and proper setup.
Note: When filling in the OPCP worksheet I used a process that was implemented at Production Products Inc. for the Ford
Explorer Rear Floor Pan. I am not familiar enough with Dominos Pizza and their process from beginning to end.
3.1 BIG IDEAS. Each portion of the OPCP worksheet should have its own detail standard operating procedure. For
example: An SOP with detailed work instructions should be written for the package and labeling portion for the worksheet.
This SOP should include product counts, process in which parts are stacked, what information needs to be present on the
package label and so on.
4.1 MAIN FINDINGS. OPCP is a very straight forward document that gives general information about the flow of material
from raw material to finished product. Detailed SOP's should follow the OPCP chart and include explicit detail about the
steps in the OPCP.
5.1 STRENGTHS/WEAKNESSES. The OPCP chart can be used as a quick reference guide for anyone who needs to
know the material flow, tools used, process parameters and product characteristics.
Angel Estrada, QS-727, Fall 2009 Page 4 of 8 Assign 9, 10/12/09
Weaknesses: At first glance, the OPCP worksheet seems very cluttered. Obviously, as time goes on it will become easier
to find the information you are looking for, but maybe the worksheet arranged in a flow chart would be more useful.
6.1 PROJECT RELATIONSHIP. As Team 3 develops their project, the OPCP chart can be employed to lay out a general
process flow, product characteristics.
7.1 LEADERSHIP, EXTRA CREDIT. N/A
8.1 SELF ASSESSMENT. The work provided should be awarded an A. All requirements have been met with thoughtful
analysis and research.
Angel Estrada, QS-727, Fall 2009 Page 5 of 8 Assign 9, 10/12/09
1.2.0 Project Description
Project description is a section of the project portfolio template where the team initiates what it believes to b
throughout the course. This sheet, like most is clearly known to be dynamic, rather than static. Thus, with ea
General Assistance 1 worksheets for a given tool set assignment, this worksheet should be routinely updated per what was learne
Note that there are five boxes for objectives, and one for problem statement. All should complete and post th
routinely at the appropriate threaded site in blackboard for the course. Team leader will "distill" it out and f
or more chats focused on this and other parts of the tool and worksheet assignments. Based on experience, i
project scope should be limited to five objectives, with examples of a few provided below, to be modified an
General Assistance 2 own team work.
Based on the FACR worksheet particularly, the objectives will be modified and strengthened over time. It is
General Assist 3 project objectives will change, as all learn and focus increasingly on the project. Similarly, the project backgr
Problem Statement Improve the fuel efficiency of your personal automobile.
Project Objective 1 Project Objective 2 Project Objective 3
Improve the fuel efficiency of you The improvement of fuel efficiency Maintenance costs for
personal automobile by 15% must recover the costs of technological improvements
improvements in 1 year or less. must not exceed 20% of
This idea should be considered for the team project. Data will be readily available with proper internet resea
makes available technical and non-technical approaches for fuel efficiency improvement. The entire team sh
comprehend any of the improvements regardless of their background and experiences. Beyond team capaci
useful if implemented outside of the QS3600 classroom.
plate where the team initiates what it believes to be it's project focus
wn to be dynamic, rather than static. Thus, with each submission of
should be routinely updated per what was learned.
roblem statement. All should complete and post their views on this
r the course. Team leader will "distill" it out and finalize, based on one
nd worksheet assignments. Based on experience, it is suggested that the
mples of a few provided below, to be modified and compiled per your
will be modified and strengthened over time. It is by design that
singly on the project. Similarly, the project background
Project Objective 4 Project Objective 5
The improvements to the The first four objectives must all be
automobile must be modeled met for the project to be considered
based on documentation successful.
presented by the lean six sigma
will be readily available with proper internet research. This project
or fuel efficiency improvement. The entire team should easily be able to
background and experiences. Beyond team capacity, the project will be
QS-3600, Spring 2010
1.3 BIBLIOGRAPHIC ENTRY.Sinn, J. (2006).Lean six sigma quality transformation toolkit (LSSQTT) LSSQTT CA 1.2
Courseware content "Problem Description"
2.3 ABSTRACT. The project description worksheet is used to determine the problem statement for any six sigma model
project improvement. This worksheet should be dynamic, not static. As the project progresses the Project Description
worksheet should be updated. The project objectives articulated in the worksheet should become more refined as the team
starts to focus and research the stated problem.
3.3 BIG IDEAS. The project description worksheet should include a place for historical entries. Occasionally it is beneficial
to have the opportunity to review past objectives and ideas. The layout of the page could be set up as a calendar which will
allowing for idea and objective tacking on a weekly basis.
4.3 MAIN FINDINGS. The use of the project description worksheet allows for the team to tabulate new objectives as focus
on the project changes.
5.3 STRENGTHS/WEAKNESSES. Strengths: The worksheet is dynamic and allows for constant improvement of team
Weaknesses: Historical objectives and ideas are not represented in the worksheet.
6.3 PROJECT RELATIONSHIP. The use of the project description worksheet allows for the team to tabulate new
objectives as focus on the project changes.
7.3 LEADERSHIP, EXTRA CREDIT. N/A
8.3 SELF ASSESSMENT. The work provided should be awarded an A. All requirements have been met with thoughtful
analysis and research.
Angel Estrada, QS-727, Fall 2009 Page 8 of 8 Assign 9, 10/12/09