SIPOC -- Practical Use Use & Construction Tips Doug Stohr Lean Six Sigma Black Belt -- - MINCO 1/14/2010 1
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1 SIPOC - Practical Use & Construction Tips Doug Stohr Lean Six Sigma Black Belt -- MINCO 1/14/2010 1
2 Presentation Topics SIPOC Breakdown Construction and Tips Ranking Options SIPOC uses and Purpose SIPOC outputs - SIPOC Examples / Details 1/14/2010 2
3 SIPOC Definition High Level Flow Chart which identifies: Key Suppliers to Inputs of a process Key Inputs to a process The Process - transformation of the inputs the action steps Outputs of the transformation of inputs (CTQ, CTR,CTD,CTC CTD CTC requirements) Customers the process Outputs serve 1/14/2010 3
4 SIPOC Construction SIPOC Evaluation SIPOC Loops Know the S and C Critical Steps Share the knowledge SIPOC Details 1/14/2010 4
5 SIPOC Construction ti Use a knowledgeable process team (Critical) often cross functional Start t with Process identify all steps List what is measured at process steps Complete Outputs and if measured - list Complete Inputs next current state 1/14/2010 5
6 SIPOC Construction ti Complete Suppliers next Complete Customers check as a supplier also and for any inputs The SIPOC will help define a projects scope The SIPOC supports the Measure Stage when measurements are listed The SIPOC diagram helps fence a project s scope by defining IPO creates a visual guide for the project team 1/14/2010 6
7 SIPOC Construction Tips List all Suppliers -- is the Customer a supplier (Loop) Often Customers provide critical information and or materials Inputs must link to a Supplier Rank inputs for criticality to process 1/14/2010 7
8 SIPOC Construction Tips If the Customer is a supplier with inputs --- list these. The process itself -- transforms inputs do not over detail -- high level process steps only 1/14/2010 8
9 SIPOC S PCA / SMT Process Project Goal - Improve process FPY from 97% to 99.5% S I P O Suppliers Inputs Process Outputs Provider Stencil supplier Paste Supplier PCB Mfg Stock Room Component Kit Doc. Control Plt Compressor Conexus Power Co.
10 SIPOC SI PCA / SMT Process S I P O Suppliers Inputs Process Outputs Input requirements and Provider Stencil supplier Solder Stencil Paste Supplier Solder Paste PCB Mfg Blank PCB Stock Room Component Kit Component Kit SMT Feeder setup SMT Program Doc. Control BOM Plt Compressor Conexus Power Co. Reflow Profile & Program AOI Program Shop Air Elect
11 SIPOC- SIP PCA / SMT Process S I P O Suppliers Inputs Process Outputs Input requirements and Provider Start: Stencil supplier Solder Stencil Work Order Configured and sent to Mfg. Resources Paste Supplier Solder Paste Stock Room issues kit to SMT PCB Mfg Blank PCB Stock Room Component Kit Component Kit SMT Feeder setup SMT Program Doc. Control BOM High-Level Process Description: 1. Setup and load component carriage feeders Reflow Profile & Program 2.Select correct solder paste and stencil AOI Program 3.Select correct solder printer program Plt Compressor Shop Air 4. Solder Screen print First PCB Conexus Power Co. Elect 5. Verify first image registration of paste 6. Solder Paste Screen print PCBs Top side 7. Select correct SMT pick and place program 8. Load SMT line with component carriage feeders 9. Verify pick placement to Print & BOM 10. Populate first board and inspect 11. Select correct reflow program 12. Reflow one board and inspect 13. Select correct AOI program 14. Inspect first PCA with AOI 15. Release and run line End: Completely populated and reflowed PCA Inspected and confirmed by AOI. Moves to: Next operation or to packaging and shipping and then shipped to end customer.
12 SIPOC - SIPO PCA / SMT Process S I P O Suppliers Inputs Process Outputs Input requirements and Output requirements and Provider Start: Stencil supplier Solder Stencil Work Order Configured and sent to Mfg. Resources IPC 610 Class 2 Solder Paste Supplier Solder Paste Stock Room issues kit to SMT joints PCB Mfg Blank PCB Stock Room Component Kit Correct components per Customer print Component Kit SMT Feeder setup SMT Program Correct Polarity of Components Doc. Control BOM High-Level Process Description: 1. Setup and load component carriage feeders Reflow Profile & Program 2.Select correct solder paste and stencil Passes Board level ET AOI Program 3.Select correct solder printer program Plt Compressor Shop Air 4. Solder Screen print First PCB Passes Full Functional ET Conexus Power Co. Elect 5. Verify first image registration of paste 6. Solder Paste Screen print PCBs Top side Meets Agency Callouts 7. Select correct SMT pick and place program 8. Load SMT line with component carriage feeders Meets ROHS if required 9. Verify pick placement to Print & BOM 10. Populate first board and inspect Meets IPC Ionic cleanness level - < 10 u gms/ cm 11. Select correct reflow program 12. Reflow one board and inspect 13. Select correct AOI program 14. Inspect first PCA with AOI 15. Release and run line End: Completely populated and reflowed PCA Inspected and confirmed by AOI. Moves to: Next operation or to packaging and shipping and then shipped to end customer.
13 SIPOC COMPLETE PCA / SMT Process S I P O C Suppliers Inputs Process Outputs Customers Input requirements and Output requirements and Provider Start: Receiver Stencil supplier Solder Stencil Work Order Configured and sent to Mfg. Resources IPC 610 Class 2 Solder Electrical Test Paste Supplier Solder Paste Stock Room issues kit to SMT joints Inspection Mechanical PCB Mfg Blank PCB Assembly Stock Room Component Kit Correct components per Customer print Wash Component Kit SMT Feeder setup Post solder SMT Program Correct Polarity of Components Packaging & Shipping Customer to Doc. OEM - Contract Control BOM High-Level Process Description: Cust. 1. Setup and load component carriage feeders Reflow Profile & Program 2.Select correct solder paste and stencil Passes Board level ET AOI Program 3.Select correct solder printer program Plt Compressor Shop Air 4. Solder Screen print First PCB Passes Full Functional ET Conexus Power Co. Elect 5. Verify first image registration of paste Customer Specifications 6. Solder Paste Screen print PCBs Top side Meets Agency Regs 7. Select correct SMT pick and place program 8. Load SMT line with component carriage feeders Meets ROHS if required 9. Verify pick placement to Print & BOM Meets IPC Ionic cleanness level - < 10 u 10. Populate first board and inspect gms/ cm 11. Select correct reflow program 12. Reflow one board and inspect 13. Select correct AOI program 14. Inspect first PCA with AOI 15. Release and run line End: Completely populated and reflowed PCA Inspected and confirmed by AOI. Moves to: Next operation or to packaging and shipping and then shipped to end customer.
14 SIPOC Ranked CTQ included --- PCA / SMT Process Suppliers Risk Inputs Process Outputs CTQ Input requirements and Output requirements and Provider Rank Start: Identify Stencil supplier 2 Solder Stencil Work Order Configured and sent to Mfg. Resources IPC 610 Class 2 Solder Yes Paste Supplier 1 Solder Paste Stock Room issues kit to SMT joints PCB Mfg 2 Blank PCB Correct components per Stock Room 3 Component Kit Customer print Yes Component Kit 3 SMT Feeder setup 1 SMT Program Correct Polarity of Components Yes Customer to Doc. Control 3 BOM High-Level Process Description: 1. Setup and load component carriage feeders Reflow Profile & 1 Program 2.Select correct solder paste and stencil Passes Board level ET Yes 1 AOI Program 3.Select correct solder printer program Plt Compressor 1 Shop Air 4. Solder Screen print First PCB Passes Full Functional ET Yes Conexus Power Co. 1 Elect 5. Verify first image registration of paste Customer 2 Specifications 6. Solder Paste Screen print PCBs Top side Meets Agency Regs Yes 7. Select correct SMT pick and place program 8. Load SMT line with component carriage feeders Meets ROHS if required Yes 9. Verify pick placement to Print & BOM 10. Populate first board and inspect Meets IPC Ionic cleanness level - < 10 u gms/ cm Yes 11. Select correct reflow program 12. Reflow one board and inspect 13. Select correct AOI program 14. Inspect first PCA with AOI 15. Release and run line
15 Suppliers Risk Inputs Process Outputs CTQ Input requirements and Output requirements and Provider Rank Start: Identify Stencil supplier 2 Solder Stencil Work Order Configured and sent to Mfg. Resources IPC 610 Class 2 Solder Yes Paste Supplier 1 Solder Paste Stock Room issues kit to SMT joints PCB Mfg 2 Blank PCB Stock Room 3 Component Kit Correct components per Customer print Yes Component Kit 3 SMT Feeder setup Correct Polarity of 1 SMT Program Components Yes Customer to Doc. Control 3 BOM High-Level Process Description: Yield good / bad 1. Setup and load component carriage feeders Reflow Profile & 1 Program 2.Select correct solder paste and stencil Passes Board level ET Yes 1 AOI Program 3.Select correct solder printer program Plt Compressor 1 Shop Air 4. Solder Screen print First PCB Passes Full Functional ET Yes Conexus Power Co. 1 Elect 5. Verify first image registration of paste Customer 2 Specifications 6. Solder Paste Screen print PCBs Top side Meets Agency Regs Yes 7. Select correct SMT pick and place program 8. Load SMT line with component carriage feeders Meets ROHS if required Yes 9. Verify pick placement to Print & BOM 10. Populate first board and inspect Meets IPC Ionic cleanness level - < 10 u gms/ cm Yes 11. Select correct reflow program 12. Reflow one board and inspect 13. Select correct AOI program 14. Inspect first PCA with AOI 15. Release and run line End: Completely populated and reflowed PCA Inspected and confirmed by AOI % yield meets print. Moves to: Next operation or to packaging and shipping and then shipped to end customer.
16 SSIPOC ASQ Dinner Meeting Process Suppliers Inputs Process Outputs Customers Input requirements and Output requirements and Provider Start: ASQ Dinner Meeting Selection - Process Receiver High-Level Process Description: ASQ Program Committee Member meeting Survey information Program Committee meets Meeting Improvement action ASQ Members Membership Profile Program Selections discussed Meeting topic selected ASQ Program Committee ASQ Members Speaker Lists Programs proposed Meeting Speakers Selected Meeting Topic List Program voted on & selected Meeting location selected Last meeting member ASQ National Org. survey results Speaker - research assigned Meeting Meal Selected Past meeting attendance records Location - research assigned Meeting promotion completed Quality and Industry Past meeting location Magazines information Presenters - proposed Past meeting meal selection Presenter Selected Presenter contacted - affirmed Quality Topic Publication information Location proposed Location affirmed and reserved Meal proposed Meal Selected Meeting notice and details published in News Letter Payments collected Meeting held and feedback collected End Dinner meeting conducted and feedback reviewed by program committee at next meeting for improvement and success - did the meeting meet the ASQ members needs and expectations
17 SIPOC Example - Final Inspection Process S I P O C Suppliers Inputs Process Outputs t Customers Provider Input requirements and Start: Final Inspection Process Output requirements and Receiver High-Level Process Description: Manufacturing Final Inspection Procedure Product staged for inspection Completed final Inspection record Shipping Tagged Inspection status Engineering Finished Product Insp Procedure pulled per Product Part Number Finished Product Stock room Customer Sampling Plan Inspection tools selected per procedure Move Tag Distribution Center Material movement Doc. Control Inspection Equipment Product Specification pulled Reject Tag operator Quality Engineering Specifications Customer Prints pulled Accept Tag Purchasing Customer Facilities Customer Prints Cosmetic Criteria Specification pulled Stamped container Insp Status NCM area Cosmetic Standards Sample table pulled NCM if rejected Inspection Record Form Sampled size selected per Inspection procedure Inspection Status Tag Sample Product measured Inspection Work area / station Measurement results recorded Cosmetic Inspection results recorded Pass / Fail decision made and recorded Product marked as passed ready to move. End Inspection complete and results recorded and product status marked and moved according to pass / fail status
18 SIPOC Analysis Tips Use the SIPOC to identify Suppliers that may impact project success Stop and look at bad or problematic Suppliers for action may require action before project started Projects are directed at improving an output Project scope fits inside the SIPOC The Input Process Outputs define scope 1/14/
19 SIPOC Analysis Tips Use VOC (Voice of the Customer) Customer s should agree with outputs Have Customers review outputs SIPOC helps find key customers of the Project - by listing them Rank SIPOC inputs and outputs to help determine project focus shows weak or risk areas Ranking helps a project with impact 1/14/
20 SIPOC Critical Project Guidance Tool Benefits Provides easy to see process boundaries Critical project scope tool Easy to use Fences project boundaries Directs project effort 1/14/
21 SIPOC Critical Project Guidance Tool Benefits Stops a project from failing at start by helping with a bad supplier or input Provides risk points for analysis Supports VOC Identifies C & M elements Constraints and 1/14/
22 SIPOC Critical Project Guidance Tool Benefits Provides CTQ, CTR,CTD,CTC identifiers Provides key customers Provides key outputs and Acts as part of the project road map 1/14/
23 Any Questions s?????? THANK YOU I hope you found this tool brief helpful Best Regards Doug Stohr MINCO Lean Six Sigma Black Belt 1/14/
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