Free Process Capability Calculator

Knowing if a process will consistently meet specification is critical, here’s a tool that will help.

You have to manage a system. The system doesn’t manage itself.
W. Edwards Deming

A process is a unique combination of tools, materials, methods, and people engaged in producing a measurable output; for example a manufacturing line for machine parts. All processes have inherent statistical variability which can be evaluated by statistical methods…

The Process Capability is a measurable property of a process to the specification, expressed as a process capability index (e.g., C_pk or C_pm) or as a process performance index (e.g., P_pk or P_pm). The output of this measurement is usually illustrated by a histogram and calculations that predict how many parts will be produced out of specification.

Process capability is also defined as the capability of a process to meet its purpose as managed by an organization’s management and process definition structures ISO 15504.

Two parts of process capability are:

1) Measure the variability of a process, and

2) Compare that variability with a proposed specification or product tolerance.

You can use Minitab to complete process capability studies. For example, Keith Bower has produced some excellent overviews here and here. You can also check out his video below.

If you don’t have access to Minitab, then download my free Excel based calculator by clicking the download link below:

http://www.box.net/shared/hgbcv1c81n

You may also want to download a brief overview of process capability by clicking on the download link below:

http://www.box.net/shared/73ayxyfdsi

Read more here:

4-B Process Capability

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Can Lean and ISO 9001 be integrated?

photo credit: ClockworkGrue

In a word: yes. However, you must take care; from Wikipedia:

• “ISO 9000 guidelines provide a comprehensive model for quality management systems that can make any company competitive.”
• “A survey by Lloyd’s Register Quality Assurance indicated ISO 9000 increased net profit… Another Deloitte-Touche survey reported that the costs of registration were recovered in three years.”
• “Good business judgment is needed to determine its proper role for a company.”
• “The ISO registration process has become a mountain of paperwork. Opponents claim that it is only for documentation. Proponents believe that if a company has documented its quality systems, then most of the paperwork has already been completed.”
• “Registration… unfortunately has become a vehicle to increase consulting services… Studies show that the majority of certifications derive from customer demands, such as a vendor qualification checklist, instead of internal needs to improve quality.”
• “Is certification itself important to the marketing plans of the company? If not, do not rush to certification.”
• “Even without certification, companies should utilize the ISO 9000 model as a benchmark to assess the adequacy of its quality programs.”

Properly implemented ISO9001 provides for the success of Lean programs with provisions for:

• Management vision, direction, authorization and involvement
• Resource evaluation and application, inclusive of personnel qualification and training, processes, etc.
• Planning functions
• Qualification and control of designs, technologies, processes, materials, products and services
• Review and analysis of results, application of decision-making processes and initiation of needed changes.

The intent of ISO 9001 is to improve business processes. Lean tools are process-focused and provide the means to remove non-value activities from both the manufacturing and transactional processes. It helps improve the efficiency of the organization, its operations and its economic performance as well as the quality of its products and services. ISO 9001:2000 item 8.5.1, continual improvement, states that; “organizations shall continually improve the effectiveness of the quality management system.” A key requirement to comply with this clause, the organization must develop a process to measure, monitor and continually reduce process and product variation (evaluated by process sigma levels). Kaizen” translates into “Continual Improvement” and by reduces waste and non-value added activities. Infact, Pheng argues that the integration of ISO 9001:2000 requirements with 5-S would lead towards TQM (PHENG, L.S. (2001) Towards TQM: integrating Japanese 5-S principles with ISO 9001:2000 requirements. TQM Magazine. Vol 13, No 5. pp.334-340.).

Has your implementation of ISO9001 helped your Lean efforts?

Free Six Sigma Program Management Spreadsheet

Here’s a fantastic free six sigma program management template.

There are generally two classes of software used to support Six Sigma:

• Analysis tools, which are used to perform statistical or process analysis
• Program management tools, used to manage and track a corporation’s entire Six Sigma program

Analysis tools

• EngineRoom by MoreSteam
• IBM WebSphere Business Modeler
• iGrafx Process for Six Sigma
• JMP
• Microsoft Visio
• Minitab
• SigmaXL
• Software AG webMethods BPM Suite
• Statgraphics
• STATISTICA
• Telelogic System Architect
• Actuate
• The Unscrambler
• Select Architect Business Process Modeling

Whilst these tools are great for isolated data analysis, I believe six-sigma software really comes into its own when you’re using it to manage an entire program:

The Six Sigma methodology relies on projects, programs, resources, processes and project management to drive continuous improvement. It quantifies all feedback and allows organizations to focus on activities that must change in order to achieve desired results. With the proper IT infrastructure and flexible Six Sigma program management software, accuracy and control can be achieved, enabling your company to execute the program smoothly. Data sources will be reliable, results can be monitored and validated in real time and success shared throughout the organization.

So with this in mind, you can click on the link below to download a fantastic free six sigma program management template. The template itself runs through an entire DMAIC project and suggests a number of tools and techniques which you can use at various stages. I found it to be of enormous benefit, providing a structure to my improvement activities.

Enjoy!

Click to download the free six sigma program management template

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