Cause and Effect Matrix

Black Belt Training Module #5

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

The Breakthrough Strategy

Define
Measure Characteri1e 0naly1e
" $ & ( * BB Works with Management 1 Select Output Characteristic and identify key process input and output variables Define !erformance Standards #alidate Measurement System %stablish !roduct Capability Define !erformance Ob'ectives )dentify #ariation Sources Screen !otential Causes Discover #ariable ,elationships %stablish Operating .olerances

)mprove Optimi1e Control

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

+ -

1/ #alidate Measurement System 11 Determine !rocess Capability 1 )mplement !rocess Controls

2

Measurement Phase
Project efinition! " Pro#lem escri$tion %&uthori'e($$t) " Project Metrics %Metrics(xls) Process Ex$loration! " Process *lo+ iagram " C,E Matrix- P*ME&- *ish#one iagrams " ata collection system Measurement System%s) &nalysis %MS&)! " &ttri#ute . /aria#le 0age Studies Ca$a#ility &ssessment %on each 1) " Ca$a#ility %C$k- P$k- s 2e3el- P4- 5T1) 0ra$hical , Statistical Tools Project Summary " Conclusion%s) " 6ssues and #arriers " 7ext ste$s Com$leted 82ocal Project 5e3ie+9
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

escri$tion! Cause and Effects Matrix

:ill em$hasi'e the im$ortance of understanding the customer re;uirements 4sed to relate and $rioriti'e <=s to customer 1=s through numerical ranking using the $rocess ma$ as the $rimary source 1>s are scored as to im$ortance to the customer <>s are scored as to relationshi$ to out$uts 5esult! Pareto of <>s +hich can #e used as a starting $oint in the e3aluation of the *ME& and control $lans This tool +ill allo+ everyone in3ol3ed +ith a $rocess to agree on the out$uts that are critical to the $roduct and . or customer /ia numerical ranking- this matrix +ill allo+ your team to assign a le3el of im$ortance to each out$ut 3aria#le Through association- the matrix +ill allo+ a team to numerically assess the effect of each < on each 1 This is the teams first sta# at determining 2 3 f 4 5 6
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Process Ma$ to #e 4sed in Exam$le

)7!8.S
Bun Burger Condiments Cooking time Cooking Tem$ Packaging Procedure

Burger 0ssembly

O8.!8.S
&$$earance Taste Smell *reshness Consistency Tem$erature

Cook Burger Burger Cook Tem$ Cook Time

&ssem#le Burger Bun Condiments &ssy( Procedure

:ra$ &ssem( Burger :ra$$er :ra$ Procedure

Store ?eat 2am$ Store Time

Sell

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Ste$ @) Exam$le
19 :ist key outputs 42;s6
5ating of 6m$ortance to Customer @ &$$earance A B C 5 Consistency D Tem$erature E F G @H @@ @A @B @C @5

Cause and %ffect Matri5

Process 6n$uts @ A B C 5 D E

*reshness

Smell

Taste

Total H H H H H H H

STEP @ 2ist the out$ut 3aria#les %1=s) along the to$ section of the matrix( These are out$uts +hich the team and . or the customer deem to #e im$ortant( These may #e a su#set of the list of 1=s identified on the $rocess ma$(
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Ste$ A)
Cause and %ffect Matri5
5ating of 6m$ortance to Customer E @ &$$earance @H A F B @H C E 5 Consistency F D Tem$erature E F G @H @@ @A @B @C @5

9 ,ank outputs by importance to Customer

Process 6n$uts @ A B C 5 D E F

*reshness

Smell

Taste

Total H H H H H H H H

STEP A 5ank each out$ut numerically using an ar#itrary scale %$ossi#ly @I@H)( The most im$ortant out$ut recei3es the highest num#er(
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Ste$ B)
@ A B C 5 D E F G @H @@ @A @B @C @5 Tem$erature Consistency &$$earance *reshness

"9 :ist the key inputs STEP B 6dentify all $otential in$uts or causes %<=s) that can im$act the 3arious 1=s and list these along the left hand side of the matrix(

Process 6n$uts @ A B C 5 D E F G @H @@ Bun Burger Cook Time Cook Tem$ Condiments &ssem#ly Procedure &ssem#led Burger :ra$$er :ra$ Procedure ?eat 2am$ Tem$ Storage Time

Smell

Taste

Total H H H H H H H H H H H
8

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Ste$ C) 0uidelines
1ou are ready to 8correlate9 customer re;uirements to the $rocess in$ut 3aria#les &ssignment of the scoring takes the most time To a3oid this- s$ell out the criteria for each score %exam$les)!
" H J 7o correlation " @ J The $rocess re;uirement only remotely affects the customer re;uirement " C J This in$ut 3aria#le has a moderate effect on the customer re;uirement " G J This in$ut 3aria#le has a direct and strong effect on the customer re;uirement

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Ste$ C)
5ating of 6m$ortance to Customer E @ &$$earance @H A F B @H C E 5 Consistency F D Tem$erature E F G @H @@ @A @B @C @5

Process 6n$uts

*reshness

$9 Correlate <;s to 2;s

Smell

Taste

Total

STEP C 7umerically rate %correlate) the effect of each < on each 1 +ithin the #ody of the matrix( This is #ased on the ex$erience of the team(

@ A B C 5 D F G

Bun Burger Cook Time Cook Tem$ Condiments &ssem#ly Procedure :ra$$er

C B E E @ G 5 5 @ G

G E E D @ @ @ @ @ F

C D @ @ @ @ @ @ @ C

G F C C @ C D 5 F G

G F F F @ F @ @ D G

5 F F E @ D D @ G 5

BCB BBG AFE ADG 5H AA5 @DF @@F A@G BDF

:ra$ Procedure ?eat 2am$ @H Tem$ @@ Storage Time

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

10

Ste$ 5)
5ating of 6m$ortance to Customer E @ &$$earance @H A F B @H C *reshness E 5 Consistency F D Tem$erature E F G @H @@ @A @B @C @5

&9 Cross= multiply and prioriti1e

Total

Process 6n$uts

@ A B C 5 D F G

Bun Burger Cook Time Cook Tem$ Condiments &ssem#ly Procedure :ra$$er

C B E E @ G 5 5 @

G E E D @ @ @ @ @

Smell C D @ @ @ @ @ @ @

Taste

G F C C @ C D 5 F

G F F F @ F @ @ D

5 F F E @ D D @ G

BCB BBG AFE ADG 5H AA5 @DF @@F A@G

:ra$ Procedure ?eat 2am$ @H Tem$

We now start getting a feel for which variables are most important to e5plaining variation in the outputs9

STEP 5 4se the totals column to analy'e and $rioriti'e +here to focus your effort +hen creating the $reliminary *ME&(
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

11

Exam$le I Pareto of <>s

We have sorted on the cross=multiplied numbers and find that>
Storage time#un and #urger in$uts are the most im$ortant( :e can no+ e3aluate the control $lans for these <>s
5ating of 6m$ortance to Customer E @ &$$earance @H A F B @H C *reshness E 5 Consistency F D Tem$erature E F G @H @@ @A @B @C @5

Process 6n$uts @ B C E D F G A @H Storage time Bun Burger Cook Time Cook tem$ &ssem#ly Procedure ?eat 2am$ Tem$ :ra$$er :ra$ Procedure

Smell

Taste

Total BDF BCB BBG AFE ADG AA5 A@G @DF @@F
12

G C B E E G @ 5 5

F G E E D @ @ @ @

C C D @ @ @ @ @ @

G G F C C C F D 5

G G F F F F D @ @

5 5 F F E D G D @

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

The Method
STEP @ 2ist the out$ut 3aria#les %1=s) along the to$ section of the matrix( These are out$uts +hich the team and . or the customer deem to #e im$ortant( These may #e a su#set of the list of 1=s identified on the $rocess ma$( STEP A 5ank each out$ut numerically using an ar#itrary scale %$ossi#ly @I@H)( The most im$ortant out$ut recei3es the highest num#er( STEP B 6dentify all $otential in$uts or causes %<=s) that can im$act the 3arious 1=s and list these along the left hand side of the matrix( STEP C 7umerically rate %correlate) the effect of each < on each 1 +ithin the #ody of the matrix( This is #ased on the ex$erience of the team( STEP 5 4se the totals column to analy'e and $rioriti'e +here to focus your effort +hen creating the $reliminary *ME&(
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

13

2inks To Kther Tools

C?% Matri5
5ating of 6m$ortance to Customer G @ G A E B Cleanliness @H C @H 5 ?omogeneity G D Consistency B E igets Time A F Tem$erature D G @H @@ @A @B @C @5 0el Time

ts u p ut

/iscosity

Process 6n$uts Scales &ccuracy Preheating 6C1 TL M* 2oad &ccuracy M* Cleanliness M* 5a+ Materials 6C1 2oad &ccuracy 6C1 En3ir( *actors 6C1 5a+ Materials 6C1 Mixer S$eecd

Solids

Color

Total

@ A B C 5 D E F G

G @ B @ @ G F F @

F @ F @ @ E 5 5 @

A @ @ C @ @ B @ @

@ @ @ A @ @ @ @ @

@ @ @ @ @ @ @ @ E

G @ F A A G F G @

@ @ @ @ @ @ @ @ @

@ @ B @ @ @ @ @ @

F @ F @ @ A A A @

BA@ D5 A55 @H5 EC ADG ACE ACA @A5

)n p

ut s

Capability Summary
Fey !rocess Output #ariable Capability Status Sheet
Customer ,eBuirement 4Output #ariable6 Del .ime #iscosity Cleanliness Color Eomogeneity Consistency Digets .ime .emperature Solids Measurement .echniBue C,?, or !A. ,atio 8pper Spec :imit .arget :ower Spec :imit Cp Cpk Sample Si1e Date 0ctions

Control !lan Summary

Operational %5cellence Control !lan

@M%0
!rocessA!roduct @ailure Modes and %ffects 0nalysis 4@M%06
Process or Product 7ame! 5es$onsi#le! Pre$ared #y! *ME& ate %Krig) MMMMMMMMMMMMMM %5e3) MMMMMMMMMMMMM

Product! Ley Contact! Phone!

Core Team!

ate %Krig)! ate %5e3)!

!rocess

!rocess Step

)nput

Output

!rocess Specification 4:S:G 8S:G .arget6

Cpk ADate

Measurement .echniBue

C,?, !A.

Sample Si1e

Sample @reBuency

Control Method

,eaction !lan

D)C2 DM@ DM@ D)C2 D)C2 D)C2 D)C2

.urn Steam on Scales &ccuracy :oad DM@ :oad DM@ :oad D)C2 :oad D)C2 :oad D)C2 :oad D)C2 :oad DM@ M* 2oad &ccuracy M* Cleanliness 6C1 En3ir( *actors 6C1 2oad &ccuracy 6C1 5a+ Materials 6C1 Mixer S$eecd M* 5a+ Materials

.he Fey Outputs are listed and evaluated9

DM@

!rocess StepA!art 7umber S$in ra+ Process

!otential @ailure Mode *i#er Breakouts

!otential @ailure %ffects 4ndersi'ed $ackage- ?igh S $anelIhours lost

S % # A

!otential Causes irty S$inneret *ilament motion

O C C F A

Current Controls /isual etection of :ra$s and #roken *ilaments /isual SightIglass

D % . G F

, ! 7 @CC FH @CC H

D)C2

.urn Steam on Preheating 6C1 TL

5 Polymer defects F

*u''#all 2ight A G

.he Fey )nputs are evaluated

14

Fey )nputs are e5plored

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Ca$a#ility Summary
Customer ,eBuirement 4Output #ariable6 .emperature .aste Smell @reshness Consistency 0ppearance Measurement .echniBue Thermometer 2ikert Scale C,?, or !A. ,atio @HN 8pper Spec :imit @5H deg .arget @CH deg :ower Spec :imit @BH deg Cp A Cpk @(DE Sample Si1e BH Date A.AE.HA 0ctions

.he purpose of this worksheet is to guide actions needed to get statistical capability data9 .he form addresses both the measurement systems and the process capability9 0ny blank spaces in the form need to be addressed by actions9
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

15

Control Plan Exam$le

Control !lan
Product! Ley Contact! Phone! ?am#urger Chris EAGCE Core Team! Ted- Bill- Mary ate %Krig)! ate %5e3)! A.AE.HA

!rocess

!rocess Step

)nput

Output

!rocess Specification 4:S:G 8S:G .arget6 1"/ = 1&/ deg

Cpk ADate

Measurement .echniBue

C,?, !A.

Sample Si1e

Sample @reBuency

Control Method <=bar Chart

,eaction !lan 0d'ust .emp9

Eamburger 0ssembly

Storage

Eeat :amp

.emp

19(* A = *=/

.hermometer

1/

1//

1Aday

@or every input in the C?% matri5 !aretoG an initial assessment of the control plan is done9 .his helps pick low hanging fruit at the front end of a process improvement pro'ect9
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

16

Ouestions a#out 6nitial Control Plan 6tems

Standard K$erating Procedures " o they existP " &re they understoodP " &re they #eing follo+edP " &re they currentP " 6s o$erator certification $erformedP " 6s there a $rocess audit scheduleP Controlla#le <>s " ?o+ are they monitoredP " ?o+ often are they 3erifiedP " &re o$timum target 3alues and s$ecifications kno+nP " ?o+ much 3ariation is there around the target 3alueP " ?o+ consistent are theyP Kther Ouestions " ?o+ often is an < out of controlP " :hich <>s should ha3e control chartsP
Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

17

&$$roaching the C,E Matrix %CT Matrix)

Project Selection " Phase 6 Place the #usiness metrics %CT>s eli3ery- Cost- Ouality) across the to$ of the matrix and rank Place the $roducts do+n the left side of the matrix Correlate each $roduct to each CT Pareto the $roducts " Phase 66 Start a ne+ C,E Matrix +ith Products across the to$ and then $lace the $rocesses that su$$ort these $roducts do+n the side Correlate each $rocess to each $roduct( This identifies a $otential $roject " Phase 666 Place the $rocess out$uts across the to$ of the matrix and rank Place the in$uts do+n the side of the matrix starting +ith the first $rocess ste$ and mo3ing to the last
18

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

Coffee Exercise
Work in teams to develop C&E matrix. Rate inputs as a function of each output. Discuss how you would get customer importance ratings !areto your results. Report out top three inputs.

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

19

Coffee Exercise C,E Matrix

Cause and %ffect Matri5
,ating of )mportance to Customer @ A B Tem$erature C 5 D E F G @H @@ @A @B @C @5

&roma

Taste

Color

Total

!rocess )nput @ A B C 5 D E F G @@ @A @B @C @5 :ater Coffee *ilter ?eat Measuring cu$ Bre+ing Method

Visteon Corporation Mod #5 Cause &Effect Rev 1.0 3/02

20