Basic Problem Solving (BPS) -
Project Document
Project Title
Process/Product
TQM to achieve our business goals…
Project Leader Sponsor Name
(Mob No.) (Mob No.)
PS Facilitator/s
Project Code
Name
Unit Function
Start Date (Actual) End Date (Actual)
CFT Members
Quality Month’2015
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AL-BPS Methodology
Charter, Teaming, Pareto, Project
All possible ‘X’s Problem Management, Matrix diagram
Gemba visit, Check sheet, SPC,
Observation
Stratification, Histogram
Analysis Stratification, Pareto, Fishbone diagram,
Scatter diagram, Concentration chart, SPC
Brainstorming, Solution development, Risk & Cost
Action benefit analysis, Pilot implementation
Check Check sheet, Histogram, Pareto, Run charts, Full
scale implementation, SPC
Standardize Check sheet, SPC
Conclude Pareto, Matrix diagram, Finance vetting, Way forward
Few ‘X’s
Acknowledgements, Future projects
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Project Selection Grid – 2x2 Matrix
Complexity Score Assessment
Rating Rating guidelines
S.No. Complexity Driver Weightage
(1,3,9) 1 3 9
C1 Frequency of the problem 20 3 Rarely Sporadically / Irregular Regularly / Perennial
Multiple processes in
Multiple plants /
C2 Scope at process level 20 3 Single process Single plant / Single
Multiple Locations
Location
Across segment &
Selective models (within
C3 Scope at product level 20 1 Single model across models (as
segment)
applicable)
Semi or Partially
C4 Degree of process mechanization 20 1 Manual Fully mechanized
mechanized
Potential causes known Root causes not
All Root causes identified
based on past experience known, data
C5 Knowledge about root cause 20 3 & validated;
/ gut feel, yet to be collection and
implementation required
validated with data analysis required
Complexity Score 24%
Impact Score Assessment
Rating Rating guidelines
S.No. Impact Driver Weightage
(1,3,9) 1 3 9
Financial savings (or)
I1 Opportunity loss (in case of non 20 3 < 3.0 Lakhs 3 - 10 Lakhs > 10 Lakhs
cost reduction/non-mfg projects)
Direct impact on Internal
Indirect impact on the Direct impact on End
I2 Impact on customer 20 3 Customer; Indirect impact
internal customer customer
on End Customer
Plant function /
Impact on process/ Shop / Department Business / Company
I3 20 3 Corporate function level
business/stakeholder level metrics level metrics
metrics
I4 Gap between target and actual 20 9 Less than 25% Between 25% to 50% Greater than 50%
Across AL / More
Atleast one direct
I5 Horizontal deployment 20 9 No direct opportunity than one direct
opportunity
opportunity
Impact score 60%
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Step 1 : Problem Identification
Project Charter
Project Project Leader Unit /
Code Name Function
Project Title
Problem
Definition
In Scope
Project Goal Metric Baseline To be Benchmark
calculated
Cost Savings (INR) Intangible
Benefits
Customer Linkage to
Sponsor KRA
Time Lines (Planned) Project Start Project End date
date
Problem Selection Analysis Action
Check Conclude Lead Time
(Days)
Support Required
Approvals
Quality Month’2015
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Step 1 : Problem Identification
Project Charter
Project Project Leader Unit /
Code Name Function
Project Title
Problem
Definition
In Scope Out of Scope
Project Goal Metric Baseline Target Benchmark
Cost Savings (INR) Intangible
Benefits
Customer Linkage to
Sponsor KRA
Time Lines (Planned) Project Start Project End date
date
Problem Selection Observation Analysis Action
Check Standardize Conclude Lead Time
(Days)
Support Required
Approvals
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Project CFT – Details
Name (with Initials Time commitment Photo
# Roles & Responsibility Function
& mobile no) required (Stamp size)
1.
2.
3.
4.
5.
6.
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Gantt Chart
Project Planning – Plan Vs Actuals
Timelines Plan /
Jun W1 Jun W2 Jun W3 Jun W4 Jul W1 Jul W2 Jul W3 Jul W4 Aug W1 Aug W2 Aug W3 Aug W4
/ Phase Actuals
P
Problem
A
P
Observation
A
P
Analysis
A
P
Action
A
P
Check
A
P
Standardize
A
P
Conclude
A
Legend (for Actuals row): Task Completed All cells in Green color
Task initiated but not yet completed All cells in Yellow color
Quality Month’2015
Task not yet initiated All cells in Red color
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Problem Background & Impact
• Guideline - Pareto / Pie-chart / Monthly trend / Bar chart
• Use Matrix diagram (if required)
Inference :
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VOC & Defects “as-is” – Photos
• Insert communication from Customer
• Paste the defect photo as received from the Customer
Inference :
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Step 2 : Observation
Process Flow Diagram
• List Process flow
OP 10 OP 20 OP 30 OP 40 OP 50
Inference :
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Awareness Creation – Initiatives
Communication Mode
# Initiative Frequency Gemba Resp EDC RYG
(Mail/Displays/Speech etc)
Project Metric
1 Trend Monitoring
& sharing with CFT
• Project metric trend graph (paste)
Inference :
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Data Collection Plan
Type of Data Data Who will Data Method
Inputs / Sample
Formula (Variable / Source Collect Collection of Collecting
Outputs Size
Discrete) & Location the Data? Frequency data
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Gemba Observation (Defects / Abnormalities)
• Use Check Sheet / Data collection format
• Graph / photo
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CFT Meetings – Record of Discussions
Review / Total no of Total no of
Place / Members Participated Embed
No Date Discussion Members Members
Location (Initials in CAPS) MOM
with Planned Attended
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Pareto Analysis / Histogram
• Graph / photo
Inference :
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Step 3 : Analysis
Brainstorming / Idea Generation
Topic:
Date: Venue:
Participants Name:
1. 4.
2. 5.
3. 6.
Ideas:
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
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Fish Bone Diagram
Man Machine Material
Cause-1 Cause-1
Cause-1
Cause-2 Cause-2
Cause-2
Cause-3 Cause-3
Cause-3
Cause-4 Cause-4
Cause-4
Cause-5 Cause-5
Cause-5
Effect
Cause-1
Cause-1 Cause-1
Cause-2
Cause-2 Cause-2
Cause-3
Cause-3 Cause-3
Cause-4
Cause-4 Cause-4
Cause-5
Cause-5 Cause-5
Method Measurement Environment
Inference :
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Why-Why Analysis
Why
Why
Why
• [Text]
Why
• [Text]
Why
Inference :
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Scatter Diagram / Concentration Chart
• Use if applicable
• Use Microsoft-Excel scatter diagram
• For Concentration chart, pictorial representation of
component / part with consolidation of the defects in
areas or zones to be highlighted
Inference :
Quality Month’2015
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Root Cause/s – Photo/s
• Paste photo of the root cause/s
• Compress photo size to minimize file size
Inference :
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Tollgate Review (Till Analyze phase)
Phase Key Milestones RYG Remarks (if any)
Charter Finalization & Sign off by Sponsor
Problem
Estimate cost benefit in INR
Identification
Voice of Customer
Gemba Observation
Observation
Data collection plan formulation
CFT Meetings / Discussion as per Plan
Analysis Awareness Creation / Trend monitoring as per Plan
Root Cause Analysis (RCA)
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Step 4 : Action
Solution Development & Consensus
Topic:
Date: Venue:
Participants Name:
1. 4.
2. 5.
3. 6.
Ideas:
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
Inference :
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Solution Selection
Difficult to
Cost of Time to
implement (1-
Implementation implement (1-10) Grand
# Solutions (1-10) 1= least time
10) Rank
1= least Total
1= least cost required
difficult
Note: List all Potential Solutions with CFT and then brainstorm for ranking of the factors on a
scale of 1 to 10. Each one should individually rate first, and finalize with the consensus of CFT.
Inference :
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Risk Analysis
(Change Management actions)
# Risk mitigation Respons- Approval Deadline RYG
Solution Potential risks
. plan -ibility Authority Date Status
4
.
5
.
Inference :
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Pilot Implementation Plan
(Change Management actions)
Sample Size
Respons- Deadline RYG
# Counter Measure Pilot area with
-ibility Date Status
Frequency
Implementation From date : To date:
Inference :
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Step 5 : Check for Effectiveness
• Control Chart / Pareto / Histogram (Before Vs After)
Inference :
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Full scale Implementation – Plan & Status
Sample Size
Plant / Area / Respons- Deadline RYG
# Counter Measure with
Line -ibility Date Status
Frequency
Implementation From date : To date:
Inference :
Quality Month’2015
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Tollgate Review (Action & Check phase)
Phase Key Milestones RYG Remarks (if any)
Solution Development & Consensus
Solution Selection
Action
Risk Analysis
Pilot Plan
Effectiveness Check
Check Full Scale Implementation
CFT Meetings as per Plan
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Step 6 : Standardization
• Paste Updated SOP / WIS
• Paste Updated Control Plan
• Paste Poke Yoke details (as applicable)
• Paste Automation & Visual Controls details
Inference :
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Project Metric Trend – Before Vs After
• Use Trend chart, Pareto, Control chart (as applicable) for
continuing Daily management.
• Paste project metric trend graph
Inference :
Quality Month’2015
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Before Vs After Improvement
• Use as applicable
• Before Vs After photos to be placed side-by-side, differences,
interventions done to be clearly explained
Inference :
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Sustenance Audit plan
Audit Check Reporting Non-
# Auditee Auditor When? Where?
point conformance to whom?
4
.
5
.
Inference :
Quality Month’2015
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Step 7 : Conclude
Project Benefits
• Scanned copy of the finance vetted savings sheet to be shown
• Standardized template enclosed
Inference :
Quality Month’2015
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Horizontal Deployment
# Plant / Area / Zone / Location Responsibility Deadline date Remarks
• Use if applicable
Inference :
Quality Month’2015
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Voice of customer (VOC) – After
• Paste email copy
Inference :
Quality Month’2015
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Tools Used (as applicable)
Key Tools Problem Observation Analysis Action Check Standardize Conclude
Project Charter
Gantt Chart
Pareto Analysis
VOC
Gemba Observation
Process Flow diagram
Check Sheet
C & E diagram
Brainstorming
Data Stratification
Histogram
Scatter Diagram
Concentration Chart
Risk Analysis
Cost Benefit Analysis
SOP/WI/Control Plan
Visual Controls
Poka Yoke
Control Charts
VOC Quality Month’2015
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Acknowledgements
1. Highlight CFT support
Quality Month’2015
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TQM to achieve our business goals… Journey of Excellence continues …..
Thank You ….
Quality Month’2015
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