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3-1思考流程图6σ绿带训练─基础篇(一)HoneywellInternationalInc.3-2学习目标•了解思考流程图(TMAP)之概念与价值•复习平行与序列式思考之应用•解決问题时，了解各个问题的重要性•能够建结构图形化的思考流程图•通过思考流程图的应用范例来做练习测量分析改善控制3-3应用范例•不连续制造─绿带人员在面对须决定是否以一个适当的测量系统來改进流程，可用TMAP找出并记录替代方案。•连续制造─化学工程师必须评估改变催化剂配方可能引发的问题及其对健康、安全和环境所造成的影响。•行政管理─执行计划的绿带人员必须确认并记录项目所需的支援，并找出适当的沟通渠道以整合此改善项目。•设计─为了评估现有的产品或流程，设计工程师必须记录并评估不同设计并比较其优缺点。3-4何谓思考流程图？所谓TMAP，即是当小组解决问题时，将决策背后的逻辑思考过程书面化。•包含所要解决的问题•以图形化的方式表达思考逻辑。•是一种可藉此发展策略。•是评估的过程，评估途径。•将解决问题或关键所得或所需书面化的思考与过程知识。•也可找出会危害小组努力施行结果的关键或障碍。•改善您个人解决问题的方法(帮助你“跳出固定的思考模式及从整体来看”)•是一份活的文件！•是一份地图，可帮助您了解Y=f(x)！3-5如何构造TMAP•TMAP并无特殊的格式，您可自由选用任何格式，只需以逻辑方式表达计划所面临的问题与构想即可。步骤如下：•确认计划目标。•完成上述目标有何问题？将其书写在TMAP上。•如何定其优先顺序？哪个问题应优先回答？由TMAP中昀重要的一点开始。•您要如何回答这些问题？应使用何种工具？将其记录在TMAP上。•藉由工具回答问题的过程中，获得了哪些信息？是否已回答了这些问题？将其记录下来！•是否产生了新的问题？将其记录下来,并开始下一阶段的解决问题的程序(如回到第一个步骤！)•以上的方式可依其本质或其必要性来执行，循序渐进或平行处理皆可。•记录任何个人或小组所作的假设。3-6DoILeaseorBuyMyNextCar?HowOftenDoIneedaNEWCar?IsitTypicallyEvery3to4Years?NoYesDoIhavethe20%DownPaymentMoney?DoIMaintainmyVehicleRegularly?ArethereRestrictionsontheLease?DoesmyVehicleNeedRepairsNow?ProblemStatementBuyLeaseDoIwanttoSpendthisMoneyonaCar?HowcanIputdowntheleastamountof$NoHowmanymilesDoIDrive?YesYesYesLooks&StatusWhy?Lessthan15,000milesaYear?YesNoYesNoCanIWaitforaGoodDeal?NoYesYesYes一个简单的思考流程图范例3-7分组练习是否记得我们曾经利用TMAP来决定租车或买车的范例？找出TMAP所得的结论。现在我们要求每一组建构一个TMAP,帮助你解决如何制作一杯可口的VC泡腾片饮料或听一场F4演唱会,你会收集那些资料?如何收集这些资料?3-8作业•检视下列情况，与您的小组一起建构TMAP，以表达如何根据现有的情况处理问题。•GM希望您在年终时将其准时交货率由60%提升到95%。试建造一个TMAP，表达您的小组将如何完成计划。•一连续生产化学品经理担心应如何滿足20%的额外客户订单。假使之前从未达到如此高的产能，您的小组将如何提高产出？•一生产线经理担心其VSR的RTY太低。试建构一个TMAP以找出问题，并提高其RTY。•一物流经理希望整合15个区域中心以降低成本。试建构一个TMAP以确认需要多少个区域中心、区域中心的位置及其对客户服务的冲击。3-9总结•了解提出问题在过程中的重要性。•明确这些问题有助于确认了解过程或产品程潜在的研究路径。•能制作一个TMAP，用逻辑及图形化的方式表达问题和思考方式，以找出问题的解决之道。•上述方法可视为提供过程改善计划的新方法，且特定的计划会有特定的解决方法。3-10上述工具可应用于何处？•请花5分钟时间思考并回答这个问题3-11不同型态的TMAP范例3-12IDTask&AvailableresourcesApproachtocombiningMaterialReviewMaterialforcontentModelMaterialDraftMaterialWho'sworkingonproject?Dowehaveonefromeachsector?Whatistimelineforcompletion?Whatisscopeofthetask?Whoisthecustomerorcustomers?Whataretheirexpectations?Whataretheprocessboundaries?Isthereacharterfortheteam?Whataretherequirementsoftheprocess?Arethereconflictingrequirements?-JohnHagen(Automotive).Notfromallsectors.-ForMarch2ndClass.-CombinetheEMS,Auto&Aerospacematerialtooneseamlesspackage.-BBCs,ASIManagement,SBEs,MBBs,ALA-MeldthreesectorsbestofmaterialintonewBBCTrainingProgramMaterial-ConflictofthreadoftrainingfromteachingmaterialcriticalthoughtprocessisnotevidentintheEMS,Automaterial.Week1modules(Common)-ProcessMap-FMEA-Introto6σσ-Variation/Metrics-Methodologies/PIP-NEM/GraphicalAnalysisUniqueModules:-StatisticalTolerancing-BasicStats-CapabilityAnalysis-Correlation-Finance-TeamsBuilding-PresentationModule-MinitabBasics-HS&EConsiderationsWhichtopicsaretheessentials(MIN)?Whicharebestofbest?Whataretakawaysoftheweek?Whatuniquematerialisrequired?WhatUniquematerialshouldwekeep?Howdowebalancetrainingwearetouse?(DatadumporSocraticmethod)Basedonmethodandrequirementswhatisbestwaytocombinematerial?IsthetrainingorSocraticMethodbestwaytoteach?Howdowemaintainintegrityandlevelofthecurrentprogram?Howdoweaddressdiversecustomerbase?Whatappearanceshouldthematerialhave?Whatexercisescoincidewithmaterial?Whichonesshouldwekeep?Dowetrainteamingin6sigma?-Whatsoftskillsmeetcustomerrequirements?-Usebestofbestfromallsectors.Combinewherepossible.-Combinationofbothcriticalthought(SocraticMethodandtraining)-Shouldbeaabletousebothmethodswithinamodule.-Retaincoreofmaterial,retainbestofallmodels-useotherbestpracticemodulestoreinforceBBCabilitywhereapplicable-Needforvariousexamples/casestudieswithinmaterialtomeetdiverscustomerneeds.-Usepowerpoint!-HaveabatteryofexercisesinAppendixtochoosefromusebasedonclassmakeup.-Assesssoftskillsrequirementsbasedonclass.-TeamingthroughoutBreakoutexercises,PresentationskillswiththeProjectpresentations.-Intro,Variation,BasicStats,PMAP,TMAP,MSEFMEA.-Combinebestofbothmethodsoftrainingtosupplementlearningwithkeystocriticalthought.-Seeattachedfortakaways-Uniquerequired:HS&E,-Keep:CapabilityAnalysis,C&E,CLT,Minitab,Finance-UseteamefforttocombinematerialbyusingMBBsfromallprevioussectorstostormthroughmaterial!Howdowegeneratefeedbackonmaterial?HowtomakeModifications?TimelineforMODS?DowegenerateInstructornotes?Howdowemeasureandvalidatekeylearningobjectives?Howdowemeasureeffectivenessofmaterial?Howdowestreamlineprocessforfollowonweeksmaterial?-FeedbackloopthroughtheMBBandBBmaterialteams.-ModASAP,ReleaseASAP!Useclass6astestofmaterial.-Instructornotesindividuallybutusekeylearningobjectivesw/material-UsefeedbackformsfromBBCsandassessmentofMBBsinclass.-InviteavailableMBBstoreviewthematerialaspresented.RatelearningthroughweeklyperformanceofBBCs,comparetopreviousclasses(expectationnowhigher!)-Sharebestpracticesbetweenteamsworkingonfollowonweeks.-PerformFMEAonmaterialandprocessforrevisions!!!Week1BBCurriculumTMAPAdministrativeApplication3-13Whatrotorgroupx'sdriveATPvibrationlevels?Rotorassemblyprocessmap*Stretch,balancecheck,unstretch,clock,restretchlooprepeated