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Tools and Templates
The following have been kindly contributed by Six Sigma Forum community members like you. Download and use these files freely, but please don’t distribute them to Web sites or large groups of people.
For questions regarding contributed tools or templates, e-mail the author or e-mail pbaez@asq.org. To share a tool or template of your own, submit it here.
Tools and Templates Quicklist
Pre-Control Chart (XLS, 77 KB)
Purpose or function: This tool is used in the Control stage to monitor the CTP and CTQ factors of your process. It uses a Shainin Technique to plot data into three stoplight zones; the green (go) zone, the yellow (caution) zone and the red (stop and control) zone.
Cycle phase: Control
Special instructions: Additional instructions and examples are included in the file.
Contributed by: Aseem Sharma, Six Sigma Executive, K. R. Pulp and Papers
Date: December 2, 2008
Virtual Factory (XLS, 117 KB)
Purpose or function: The Virtual Factory simulates the manufacturing process of a turned shaft used in electrical motor assemblies. The data can be used to perform many different types of analysis including Capability Studies, Regression Analysis, and others.
Cycle phase: Measure
Special instructions: Complete instructions are included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: November 26, 2008
16-Run Plackett-Burman Experiment Design Template (XLS, 553 KB)
Purpose or function: Use this template to reduce the number of potential root causes of a problem to from 12–15 down to three to seven.
Cycle phase: Improve
Special instructions: Additional instructions and examples are included in the file.
Contributed by: Aseem Sharma, Six Sigma Executive, K. R. Pulp and Papers
Date: November 20, 2008
Gage Linearity and Bias Study (XLS, 193 KB)
Purpose or function: This tool can be used to check any measurement gage in the manufacturing process for linearity over a range of reference values. It can also be used to determine whether the bias of the gage is equal to zero.
Cycle phase: Measure
Special Instructions: This tool uses a t-Distribution to determine whether linearity and bias are zero or not. Additional instructions are included in the file.
Contributed by: Aseem Sharma, Six Sigma Executive, K. R. Pulp and Papers
Date: October 31, 2008
Gage R&R with ANOVA & XbarR Analysis (XLS, 391 KB)
Purpose or function: This spreadsheet allows the user to perform a complete Gage Repeatability and Reproducibility (GR&R) study using both ANOVA and XbarR Analysis. Complete Graphical and Numerical analysis is provided. Up to three operators, ten parts and three trials can be accommodated.
Cycle phase: Measure
Special Instructions: Complete instructions are included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: October 17, 2008
NGT Multivoting Tool (XLS, 53 KB)
Purpose or function: Use this simple tool to prioritize, analyze (via a Pareto), and minimize a comprehensive list of potential root causes to the vital few.
Cycle phase: Analyze
Special instructions: Additional instructions are included in the file.
Contributed by: Aseem Sharma, Six Sigma Executive, K. R. Pulp and Papers
Date: October 6, 2008
Plackett-Burman Experiment Template (XLS, 300 KB)
Purpose or function: Use this template, after using a Multivariate Chart or similar tool, to further reduce the number of potential root causes of a problem to three or four.
Cycle phase: Improve
Special instructions: Additional instructions and examples are included in the file.
Contributed by: Aseem Sharma, Six Sigma Executive, K. R. Pulp and Papers
Date: September 24, 2008
Multivariate Chart Template (XLS, 47 KB)
Purpose or function: Use this template to capture a comprehensive list of potential root causes to a problem, commonly 12 to 15, and then systematically eliminate those with the lowest degree of variation.
Cycle phase: Analyze
Special instructions: Additional instructions are included in the file.
Contributed by: Aseem Sharma, Six Sigma Executive, K. R. Pulp and Papers
Date: September 17, 2008
Box and Whisker Plot (XLS, 64 KB)
Purpose or function: A box and whisker plot is a graphical method of displaying variation in a set of data. In most cases a histogram provides a sufficient display, however, a box and whisker plot can provide additional detail while allowing multiple sets of data to be displayed in the same graph.
Cycle phase: Analyze
Special Instructions: Instructions included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: September 3, 2008
3 Factor DOE Template (XLS, 104 KB)
Purpose or function: This template will assist you in conducting, analyzing and interpreting controlled tests to evaluate the factors that control the value of a parameter or group of parameters.
Cycle phase: Improve
Special Instructions: Instructions included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: July 3, 2008
Gantt Chart (XLS, 56 KB)
Purpose or function: This tool can be used in process planning and control to display planned and finished work in relation to time.
Cycle phase: Improve
Special Instructions: Instructions included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: July 3, 2008
Simple Linear Regression (XLS, 348 KB)
Purpose or function: This tool can be used to evaluate the relationship between two variables.
Cycle phase: Analyze
Special instructions: Enter your paired data for independent and dependant variables.
Contributed by: Robert Montoya, SSBB, Director of Systems Improvement, GRMC
Date: June 11, 2008
DPMO Calculator (XLS, 33 KB)
Purpose or function: The simple tool calculates DPMO values of your processes which can be further used to track DPMO values either daily weekly, monthly or annually. This tool can be used to track the performance of any manufacturing or transactional process.
Cycle phase: Analyze
Special instructions: This tool can also be used to track baseline performance in the Measure phase and overall performance improvement in the Improve phase.
Contributed by: Aseem Sharma, Manager of Quality Control, K. R. Pulp and Paper
Date: June 10, 2008
Process Capability Study (1500) (XLS, 5 MB warning, large file)
Purpose or function: This spreadsheet performs a complete process capability analysis for up to 1500 data points. The data is displayed using a Histogram and SPC charts. The SPC charts are evaluated for eight stability criteria. A capability analysis is performed providing a summary of the process data, values for Cpk, Ppk, and SPC limits for Individual Moving Range charts or X Bar R charts, X Median Charts, and Pre-Control charts.
Cycle phase: Measure
Special Instructions: Instructions included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: May 20, 2008
Scatter Diagram (XLS, 117 KB)
Purpose or function: This template illustrates a Scatter Diagram, also called a Scatter Plot or XY Graph. Scatter Diagrams show the relationship between an input, X and the output, Y. If a relationship exists, the input is correlated to the output.
Cycle phase: Analyze
Special instructions: ASQ Learn About Quality: Scatter Diagrams
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: April 30, 2008
Fishbone (Cause & Effect) Diagram (XLS, 39 KB)
Purpose or function: A tool for analyzing process dispersion. It is also referred to as the “Ishikawa diagram,” because Kaoru Ishikawa developed it, and the “fishbone diagram,” because the complete diagram resembles a fish skeleton. The diagram illustrates the main causes and subcauses leading to an effect (symptom).
Cycle phase: Define
Special instructions: ASQ Learn About Quality: Fishbone Diagram
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: April 25, 2008
DMAIC Toolkit (XLS, 46 KB)
Purpose or function: This simple Excel matrix shows the possible tools and techniques applicable to the DMAIC Cycle, from the Define to the Control stages.
Cycle phase: Define
Contributed by: Aseem Sharma, SSBB Consultant, PkL Consultants
Date: April 3, 2008
AHP Matrix Template (XLS, 94 KB)
Purpose or function: Preferences can be termed as a % ratio scale of priority. It can be used in both the Define and Measure phases and can be applied after gathering VOC data.
Cycle phase: Define & Measure
Special instructions: Instructions and an example are included in the additional worksheets.
Related Instructional Presentation: AHP Process Matrix and CSI (PPT, 1.8 MB)
Contributed by: Aseem Sharma, SSBB Consultant, PkL Consultants
Date: April 3, 2008
Chi Square Contingency Table (XLS, 43 KB)
Purpose or function: This spreadsheet allows the user to look for differences between groups of data. Use this spread sheet when you have proportional data.
Cycle phase: Analyze
Special Instructions: Complete instructions are included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: March 3, 2008
Stakeholder Analysis Template (XLS, 102 KB)
Purpose or function: This template shows the impact of stakeholders’ attitudes, activity, power and interest in determining stakeholder engagement strategies.
Cycle phase: Define
Special Instructions: The template is accompanied by a PowerPoint file that includes instructions on completing the template & interpreting the results.
Contributed by: Rodney Brack, MBB, Starwood Hotels & Resorts
Related Instructional Presentation: Stakeholder Analysis (PPT, 748 KB)
Date: February 12, 2008
Cause & Effects Rating Matrix (XLS, 124 KB)
Purpose or function: This tool is used to help decide which inputs from a Cause & Effects/Fishbone diagram should be addressed first.
Cycle phase: Analyze
Special Instructions:
1st tab: (group / team): Rank major categories of the output first, and then rate the inputs against the weighted output categories.
2nd tab: (individual) Copy the results as data (not formulas) and sort the results.
3rd tab: (individual) Create a Pareto graph of the sorted data.
Contributed by: Stephen Okon, Process Engineer, Tiffany & Co.
Date: January 10, 2008
Diseños de Experimentos Factoriales (Spanish language Full Factorial DOE) (XLS, 290 KB)
Purpose or function: Esta herramienta se puede utilizar para medir los resultados de combinaciones múltiples de factores. (This spreadsheet can be used to measure the results of multiple combinations of factors. An English version is forthcoming.)
Cycle phase: Mejorar (Improve)
Contributed by: Ricardo Stutz
Date: December 10, 2007
Performance Gap Matrix template (DOC, 43 KB)
Purpose or Function: The performance gap matrix is used to identify the performance gaps between one organization and a best practice leader by reducing data to common denominators.
Cycle Phase: Define
Special Instructions: Complete instructions are included in the file.
Contributed by: Cecelia McCain, ER-One Partners, Inc.
Date: October 30, 2007
Virtual (CNC) Machine Spreadsheet (XLS, 101 KB)
Purpose or Function: This spreadsheet simulates a Computer Numerical Control (CNC) shaft machining operation. Changes can be made to the Spindle Speed, Feed Rate and Depth of Cut. A single pass or double pass program can be selected. You can Copy/Paste the resulting data into another spreadsheet or software package for analysis.
Cycle Phase: Improve
Special Instructions: Complete instructions are included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: August 28, 2007
Check Sheet, Bar Chart, Pareto, Histogram Tool (XLS, 85 KB)
Purpose or Function: Track up to 10 defects on each day of the week. This tool creates a histogram, bar chart and Pareto chart using the check-sheet data.
Date: July 30, 2007
Sigma and Cost of Quality Calculator (XLS, 45 KB)
Purpose or Function: This is a quick tool which can be used anytime in a Six Sigma project which automatically calculates the sigma levels and cost of quality based upon units produced, units consumed, defects and unit price. This tool is pretty basic but is handy when you need to support quality activities.
Cycle Phase: Any
Contributed by: Steve Maxwell & Shawn Taylor, BMW
Date: June 29, 2007
Assignable Cause Log Template (DOC, 33 KB)
Purpose or Function: The Assignable Cause Log is used with process measures and control plans to document out-of-control situations occurring from nonrandom or assignable causes. A separate log is maintained for each control plan measure.
Special Instructions: Write the name of the measure in the Control Plan Measure field and the date of the incident in the first Date field. Investigate to determine the root cause of the incident, and write an explanation in the Assignable Cause Detail field. Include the type of analysis conducted, as well as the tools used (e.g., brainstorming session, data collection check sheet, etc.) Take the action necessary to remove the root cause of the variation, and write the action taken in the Action Taken field. Write the date action was taken in the second Date field, and file with the appropriate Control Plan measure.
Cycle Phase: Control
Contributed by: Cecelia McCain, ER-One Partners, Inc.
Date: June 29, 2007
Problem Analysis Using Pareto Chart (XLS, 18 KB)
Purpose or Function: This is a quick and very basic tool which can be used to capture and analyze problem occurrences.
Cycle Phase: Define
Contributed by: Anonymous contributor
Date: June 29, 2007
COPQ Template (XLS, 18 KB)
Purpose or Function: This template can be used to document and create a baseline of costs associated with materials, and resources along with failure costs such as internal failures, external failures, appraisal costs and prevention costs.
Cycle Phase: Measure
Contributed by: Jamie Burke, Quality Engineer, Honeywell
Date: March 21, 2007
Quincunx Simulator (XLS, 203 KB)
Purpose or function: This spreadsheet allows the user to perform experiments using the classic bead drop method of a Quincunx.
Cycle Phase: Analyze
Special Instructions: Red beads are held in the container at the top of the page. A funnel at the bottom of the container allows one bead to be dropped into the Quincunx. The bead falls left or right over the pins, randomizing the drop. The bead then falls into a bin at the bottom of the page. Multiple bead drops can be performed to generate a normal distribution. The target value and the degree of variation can be adjusted using the spinners on the left. A run chart at the bottom of the page displays a record of the drops.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: March 21, 2007
3 Factor DOE (XLS, 177 KB)
Purpose or Function: Allows the user to perform a 3 factor, full factorial DOE. Three factors can be studied to determine the effect of each on the desired output. The main effect of the factors, as well as their interactions, is displayed numerically and graphically. The spreadsheet generates a predictive equation allowing the user to perform "what if" analysis. The user can set a factor at any level to find the best output. If desired, the statistical significance of each factor and all two-factor interactions can be displayed.
Cycle Phase: Improve
Special Instructions: Instructions included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: March 20, 2007
Process Capability Study (XLS, 422 KB)
Purpose or function: This spreadsheet performs a complete process capability analysis. The data is displayed using a Histogram and SPC charts. The SPC charts are evaluated for eight stability criteria. A capability analysis is performed providing a summary of the process data, values for Cpk, Ppk, and SPC limits for Individual Moving Range charts or X Bar R charts, X Median Charts, and Pre-Control charts.
Cycle phase: Measure
Special Instructions: Instructions included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: March 20, 2007
FMEA Worksheet (XLS, 118 KB)
Purpose or Function: Failure Modes & Effects Analysis tool.
Cycle Phase: Analyze
Contributed by: Allan Tonkin, DOUBLE, Double Productions
Date: March 3, 2007
Process Control Plan Worksheet (XLS, 58 KB)
Purpose or Function: This tool helps individuals and users document a Process Control Plan during the Improve and Control phase of a DMAIC project.
Cycle Phase: Improve, Control
Contributed by: Allan Tonkin, DOUBLE, Double Productions
Date: March 3, 2007
X-Y Prioritization Matrix (XLS, 131 KB)
Purpose or Function: Great tool in helping to focus-in on most important factors.
Cycle Phase: Analyze
Special Instructions: Instructions included in the file.
Contributed by: Ed Wegner, Quality Manager/SSBB
Date: March 1, 2007
Project Selection Index (XLS, 40 KB)
Purpose or Function: This is a very simple tool that helps in the efficient selection of improvement projects.
Cycle Phase: Define
Contributed by: Reymundo Cortez, Six Sigma Blackbelt, Leviton
Date: February 7, 2007
Simple QFD Matrix (XLS, 42 KB)
Purpose or Function: QFD connects the voice of the customer needs and wants (the Whats) to the capabilities, techniques, or approaches (the Hows) an organization can leverage to meet those needs. It is used in the DMAIC Define step to capture the customer needs, and in the Improve step to define the "Hows" that can be implemented.
Cycle Phase: Define, Improve
Special Instructions: Input the “Whats” in the Whats worksheet and prioritize each (using a 0,1,3,9 or a 0-10 scale) – the greater the number the higher priority. Input the “Hows” in the Hows spreadsheet. Input the relationship in the Matrix worksheet. Calculations are done automatically by the spreadsheet.
NOTE: increasing the Whats or Hows columns will create macro problems. This is for simple QFD matrix to avoid the expensive of QFD software.
Contributed by: Peter Bersbach, Master Blackbelt, Bersbach Consulting
Date: February 7, 2007
Control Plan Template (DOC, 31 KB)
Purpose or Function: The Control Plan is an easy-to-use spreadsheet that is developed along with process measures to record actions and responsibilities for controlling the features and goals of a process.
Cycle Phase: Control
Special Instructions: Column 5, “Goal”, is the desired target at which you want the measure to perform. Column 8, “When to Act”, defines when action should be taken, such as root cause analysis to discover what is causing the measure to perform at an unacceptable level.
Contributed by: Cecelia McCain, ER-One Partners, Inc.
Date: December 1, 2006
Wilcoxon - Mann - Whitney Rank Sum Test (XLS, 110 KB)
Purpose or Function: This spreadsheet performs a Wilcoxon - Mann - Whitney Rank Sum Test to look for statistical differences between two groups of data. This is a non-parametric test that can be used regardless of the underlying distribution (normal, Binomial, Poisson etc).
Cycle Phase: Improve
Special Instructions: Instructions included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: December 1, 2006
SIPOC Diagram Template 2 (VISIO, 56 KB)
Purpose or function: A SIPOC diagram is used to graphically outline all the relevant elements of a process improvement project. The tool can help those newer to DMAIC to grasp the systems aspect of process definition.
Cycle phase: Define or Measure
Contributed by: Jamie Burke, Honeywell
Date: November 6, 2006
Related article: SIPOC Diagram for Process Improvement
Detailed Process Map Template (PPT, 43 KB)
Purpose or function: Detailed process maps are used to identify sources of variation, opportunities for improvement, and help characterize the relationships Y = f(x). They are helpful in identifying the key inputs (X’s) and output variables (Y’s).
Special instructions: Key inputs into the process can be classified as follows: Noise (N) - are inputs that are uncontrollable or too costly to control. Controllable (C) - are inputs that can be changed; they are sometimes called “knob” variables because they can be turned or adjusted. Standard Operating Procedures (S) - are procedures, drawings, or work instructions that do not need to be tested or changed. Critical (X) - are inputs that have a major impact on Y’s; usually unknown when first developing the process map.
Cycle phase: Define
Contributed by: Jamie Burke, Honeywell
Date: November 6, 2006
t and F Tests (XLS, 78 KB)
Purpose or function: This spreadsheet performs a two sample t test and F test at 95% confidence to look for statistical differences between two groups of data. The F test evaluates the variance of the two data sets. The t test evaluates the average (or mean) of the two data sets. The t test calculation is dependent on the results of the F test. If there is a statistical difference in the variation between the two groups, a two sample t test assuming unequal variance is performed. If a difference in the variation cannot be shown, a two sample t test assuming equal variance is performed. The test results are displayed in plain english.
Cycle phase: Improve
Special Instructions: Instructions included in the file.
Contributed by: Dean Christolear, Six Sigma Black Belt
Date: October 16, 2006
Project Ticket Template (DOC, 72 KB)
Purpose or function: This tool is used to define the framework (or charter) for a quality planning or quality improvement project. It is designed to avoid project scope creep by keeping the project focused on the defined objectives and deliverables. It also helps to identify project team members from the list of stakeholders and to expose project interdependencies.
Cycle phase: Define
Contributed by: Cecelia McCain, ER-One Partners, Inc.
Date: September 8, 2006
SIPOC Diagram template (DOC, 23 KB)
SIPOC Healthcare example (DOC, 31 KB)
Purpose or function: A SIPOC diagram is used to graphically outline all the relevant elements of a process improvement project. The tool can help those newer to DMAIC to grasp the systems aspect of process definition.
Special instructions: The center process block is where the flowchart or process map would "overlay" this tool.
Cycle phase: Define or Measure
Contributed by: Grace Duffy, ASQ Vice President
Date: August 28, 2006
Related article: SIPOC Diagram for Process Improvement
OEE Template (XLS, 48 KB)
Purpose or function: Automates the OEE calculation
once the data is entered. The second sheet helps to assess the variable
costs associated with its current performance level.
Cycle phase: Define
Contributed by: Charlie Rupert, MANN+HUMMEL
Date: June 16, 2006
Process Flow Chart (XLS, 181 KB)
Purpose or function: Template for process mapping. Designed
to be printed so that groups can fill in the forms by hand and then the
data can be transferred to electronic format for storage and graphing
analysis.
Cycle phase: Measure
Special instructions: The tables at the top of the
page, once filled out, will update the graphs automatically.
Contributed by: Charlie
Rupert, MANN+HUMMEL
Date: June 16, 2006
DPMO to Sigma Level Chart (XLS, 20 KB)
Purpose or function: A simple graphic Excel template
that will help you show before-and-after improvements in terms of DPMO
and PPMs. Can be added as a graphic to your project.
Special instructions: Can be used in projects just
to graphically show a baseline measurement and the improvements made to
the PPM level.
Cycle phase: Improve
Contributed by: Jamie
Burke, Honeywell
Date: June 12, 2006
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