These slides are part of the ESTIEM Lean Six Sigma Green Belt course which also includes 13hr of video by Gregory H. Watson. For more info about the ESTIEM Lean Six Sigma Green Belt course visit https://internal.estiem.org/leansixsigma

1. European Students of Industrial Engineering and Management
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Risk analysis
for publication
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2. European Students of Industrial Engineering and Management
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It’s Feedback time!
2
Persons giving feedback
Link to the feedback form
(can be found on Schoology and
WhatsApp)
Instructor to give feedback toPersons giving feedback
INSTRUCTOR 1
INSTRUCTOR 2

3. European Students of Industrial Engineering and Management
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What is the Y
measure?
The training today will comprise three phases
Fishbone
Potential
Problem
Analysis (PPA)
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2
3
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4. European Students of Industrial Engineering and Management
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What do you remember about DMAIC?
Project
Charter
SIPOC
EDA
VA vs.
NVA
DEFINE
Deployment
Diagram
Identifying the
Bottleneck
MEASURE
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5. European Students of Industrial Engineering and Management
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Fishbone Diagram and PPA as part of the
Measure phase
Fishbone
Diagram
Deployment
Diagram
MEASURE
PPA
Measure, Analyze
& Improve
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Identifying the
Bottleneck

6. European Students of Industrial Engineering and Management
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What methods will we use today?
Defining the
Y measure
Fishbone diagram
Potential Problem
Analysis
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7. European Students of Industrial Engineering and Management
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What is the definition of
the Y measure ?
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8. European Students of Industrial Engineering and Management
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Y = f(x)
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9. European Students of Industrial Engineering and Management
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Characteristics of a good catapult
Shoots fast
Low
Variation
Hits the
target
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10. European Students of Industrial Engineering and Management
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Why is it important to understand what
is the Y measure of the process?
Why is it important to understand what
the x measures of the process are?
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11. European Students of Industrial Engineering and Management
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Next method Fishbone diagram!
Defining the
Y measure
Fishbone diagram
Potential Problem
Analysis
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12. European Students of Industrial Engineering and Management
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What is the purpose of doing a
Fishbone diagram?
It serves as a long list of
possible factors
(x’s of the process)
affecting the Y

13. European Students of Industrial Engineering and Management
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Fishbone Diagram
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Desired
output

14. European Students of Industrial Engineering and Management
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Have you heard of the
7M categories?
Can you remember them all?
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15. European Students of Industrial Engineering and Management
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7M categories
▪ Measurements
▪ Material
▪ Methods
▪ Manpower
▪ Machinery
▪ Mother Nature
▪ Money
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16. European Students of Industrial Engineering and Management
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Fishbone Diagram
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Materials Methods
Machinery
Mother
Nature
Measurement
Manpower
Money
Desired
output

17. European Students of Industrial Engineering and Management
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Can you think of other methods
to list the factors that could
possibly affect the Y?
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18. European Students of Industrial Engineering and Management
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Time to work…
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19. European Students of Industrial Engineering and Management
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SPONSOR MESSAGE
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20. European Students of Industrial Engineering and Management
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Sometimes the items are labelled as
controllable (C) or noise (N)
What do these terms mean?
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21. European Students of Industrial Engineering and Management
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Sometimes the items are labelled as
controllable (C) or noise (N)
Why do we distinguish between the two?
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22. European Students of Industrial Engineering and Management
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SPONSOR MESSAGE
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23. European Students of Industrial Engineering and Management
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In which phase of the DMAIC process
should you use the Fishbone diagram?
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24. European Students of Industrial Engineering and Management
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Fishbone is often created in the Measure phase
but used throughout the DMAIC.
1) When suck – Helps to find a new approach.
2) New things can come up later in the DMAIC
- Add them
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25. European Students of Industrial Engineering and Management
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Ask why 5 or as many times as needed, to
identify the possible root
Are you familiar with 5 why’s technique?
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26. European Students of Industrial Engineering and Management
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Let’s think about the Method 5 Why’s
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It is to warm when distributed
Thermostat is broken
Cooling is varying
Not enough maintenance
Ice cream melts too fast
Cooling has to be adjusted manually
No maintenance planned
Why?
Why?
Why?
Why?
Why?
Why?
This causes ?
This causes ?
This causes ?
This causes ?
This causes ?
This causes ?

27. European Students of Industrial Engineering and Management
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Next we’ll jump to PPA
Defining the
Y measure
Fishbone diagram
Potential Problem
Analysis
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28. European Students of Industrial Engineering and Management
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Which tools you know can be helpful to
understand the potential risks?
Deployment Diagram
Fishbone
Potential Problem Analysis
(PPA)
EDA
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29. European Students of Industrial Engineering and Management
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Often the different risks are linked – there is
often one risk that causes several others
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Risk / Problem
Likely causes Effects

30. European Students of Industrial Engineering and Management
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Have you heard about FMEA
(Failure Mode Effective Analysis)?
FMEA is a widely used methodology for
risk analysis that was developed in the
1950s
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31. European Students of Industrial Engineering and Management
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In FMEA Risk Priority Number can be calculated
Failure Mode Severity Occurrence Detection RPN
A 4 5 10 200
B 4 8 2 64
C 9 2 1 18
0 1 2 3 4 5 6 7 8 9 10
10
9
8
7
6
5
4
3
2
1
0
SEVERITY
O
C
C
U
R
R
A
N
C
E
B
C
Risk Priority Number (RPN) = S * O * D
Which failure mode has
the biggest impact?
A
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32. European Students of Industrial Engineering and Management
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In the ESTIEM Lean Six Sigma Green Belt
course we teach the Potential Problem
Analysis which is a developed version of the
FMEA
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33. European Students of Industrial Engineering and Management
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PLAN/
ACTIONS/TA
SKS
PROBLEMS EFFECTS
LIKELY
CAUSES
SEV OCC
PREVENTIVE
ACTIONS
CONTINGENT
ACTIONS
TRIGGERS FOR
CONTINGENT
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Potential Problem Analysis (PPA)

34. European Students of Industrial Engineering and Management
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PLAN/
ACTIONS/T
ASKS
PROBLEMS EFFECTS
LIKELY
CAUSES
SEV OCC
PREVENTIVE
ACTIONS
CONTINGENT
ACTIONS
TRIGGERS FOR
CONTINGENT
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Potential Problem Analysis (PPA)
We are going to focus on this part now

35. European Students of Industrial Engineering and Management
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An example of filling PPA
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Plan / Action
/ Task
Problem Effects likely causes
Pulling the
catapult arm
Finger slips
Ball does not
fly as long as
it could
Wet finger
Shaking
hands

36. European Students of Industrial Engineering and Management
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Time to work…
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37. European Students of Industrial Engineering and Management
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SPONSOR MESSAGE
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38. European Students of Industrial Engineering and Management
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Did you find problems linked
to each other?
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39. European Students of Industrial Engineering and Management
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PLAN/
ACTIONS/T
ASKS
POTENTIAL
PROBLEMS
EFFECTS
LIKELY
CAUSES
SEV OCC
Potential Problem Analysis (PPA)
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40. European Students of Industrial Engineering and Management
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Risks are often categorized from 1-10
(10 highest)
How would categorize (1-10) the risk:
The catapult is instable
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41. European Students of Industrial Engineering and Management
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Don’t start by voting on the number values…
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Define the scale
Fill in the
risk values
Prioritize the
risks

42. European Students of Industrial Engineering and Management
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If possible, use data!
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43. European Students of Industrial Engineering and Management
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Example of the severity table
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44. European Students of Industrial Engineering and Management
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Example of an occurrence table
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45. European Students of Industrial Engineering and Management
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Matrix can be helpful to visualize the prioritizing
process for risk
Severity
Occurrence
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46. European Students of Industrial Engineering and Management
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Excel is a good tool to create a PPA
Potential problem Effect Likely causes Severity Occurance
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47. European Students of Industrial Engineering and Management
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Time to work…
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48. European Students of Industrial Engineering and Management
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SPONSOR MESSAGE
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49. European Students of Industrial Engineering and Management
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PLAN/
ACTIONS/T
ASKS
POTENTIAL
PROBLEMS
EFFECTS
LIKELY
CAUSES
SEV OCC
PREVENTIVE
ACTIONS
CONTINGENT
ACTIONS
TRIGGERS FOR
CONTINGENT
ACTIONS
Potential Problem Analysis (PPA)
49

50. European Students of Industrial Engineering and Management
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What is the difference between?
1) Preventive action
2) Contingent action
3) Trigger for contingent action
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51. European Students of Industrial Engineering and Management
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An example of the items in the case of a
burning house
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Preventive Trigger Contingent
No open fire in
house
Hear fire
alarm
Fire
extinguisher

52. European Students of Industrial Engineering and Management
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Time to work…
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53. European Students of Industrial Engineering and Management
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SPONSOR MESSAGE
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54. European Students of Industrial Engineering and Management
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Question 1/2:
Which other tools can link to the
creation of a PPA?
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55. European Students of Industrial Engineering and Management
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Question 2/2:
How should the risks be prioritised, and
why is it important to follow that process?
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56. European Students of Industrial Engineering and Management
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PPA can be started in Measure but continues
throughout Analyse, Improve & Control
Measure Analyze Improve
Potential Problem
Likely Causes
Effects
SEVERITY
OCCURANCEAction
Trigger for
contingent action
Contingent Action
Preventive Action
Need for
data!
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57. European Students of Industrial Engineering and Management
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Time for reflection and
questions
57

58. European Students of Industrial Engineering and Management
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It’s Feedback time!
58
Persons giving feedback
Link to the feedback form
(can be found on Schoology and
WhatsApp)
Instructor to give feedback toPersons giving feedback
INSTRUCTOR 1
INSTRUCTOR 2

59. European Students of Industrial Engineering and Management
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Usage license of the
materials
https://creativecommons.org/licenses/by-nc/4.0/legalcode
Contact leansixsigma@estiem.org
for commercial usage of the materials
Materials of the trainings have been created based on the materials provided by
ESTIEM Summer Academy Professor Gregory H. Watson