This document outlines the F.A.D.E.S process improvement methodology created by LCC, LLC. The F.A.D.E.S process stands for Focus, Analyze, Develop, Execute, Sustain. It incorporates elements of process improvement, project management, lean, six sigma and other tools. The methodology follows 5 phases - Focus, Analyze, Develop, Execute, Sustain - and provides examples of steps, outputs and tools that can be used in each phase such as problem statements, data collection plans, root cause analysis, solution selection, implementation planning and metrics for monitoring impact. The goal is to reduce waste, improve quality and increase margins through a disciplined and repeatable process improvement approach

1. …Operational expert committed to lasting change
“The F.A.D.E.S Solution”
Process Improvement Methodology
By: LCC, LLC (Founder – Wayne Oliver)
& John Sisti (CMQ/QE)

2. GETTING STARTED
• Are their any Enterprise Environmental Factors /EEF’s to be aware of?
(Conditions, not under the immediate control of the team, that influence or
constrain a project)
• Did you check to see if any Organizational Process Assets / OPA’s exist?
(Polices, procedures, and knowledge bases that are specific to the
organization)
• Do you have upper management sponsorship for this effort?
• Will you pre-assign initial resources?
• Did you assign a Project Manager?
• Consider a 5 “S” project as an option before starting the process?
(Sort, Shine, Set in Order, Standardize, Sustain)
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3. What is Quality?
• PMI defines quality as the degree to which a set of inherent
characteristics fulfills requirements
• What is the FADES Process? A hybrid improvement process which
incorporates Process Improvement (PDCA), Project Management (PMBOK),
Lean, Six Sigma and other tools
• F = Focus
• A = Analyze
• D = Develop
• E = Execute
• S = Sustain
• My objective is to reduce waste, improve quality and increase
margins
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4. F.A.D.E.S. PROCESS
(+)PLUS SUSTAIN
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5. FOCUS
•Phase 1
oChoose a problem and describe it.
•Output
oDefine high level project requirements and scope
oCreate a charter, gain approval
oIdentify Stakeholders
oA written statement of the problem
•STEPS
o1A Generate a list of problems – Brainstorming
o1B Select One Problem – Multi-vote or Selection Grid
o1C Verify and define the problem – Problem Statement or Impact Analysis
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6. ANALYZE
• Phase 2
o Learn about the problem from data
• Output
o A list of the most influential factors
o Root Cause Analysis (Five Why’s)
o Cost Benefit Analysis
o Baseline data
• Steps
o 2A Decide what you need to know - Checklist
o 2B Collect data, baselines and patterns – Data gathering plan, Survey, Sampling,
Check sheet
o 2C - Determine the most influential factors – Pareto Analysis, Fishbone Diagram,
Flow chart, Process Map and Linear Regression
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7. ABC COMPANY – PRODUCT FLOWCHART (Example)
Sales enters order
Receiving
enters
inserts into
Maestro
Package is
built in
Maestro and
closed for
IHD
Information is
entered into
Maestro for
Receiving and
Schedule
Pullsample For
Target Direct Sales/
CS
Weigh Verify
incoming procedure
Accept or reject
count
Refuse Load
Locate material in
racking
Material is staged
outside warehouse
Customer
sells into
zones on
UVP side
Paper Work Orders
created
Pick Ticket is created
Alphaliner Set-up
Wrap created in
house
Press Process
Printing in-house
or Outside Client
Ship to outside
Vendor
File Created for DAL
DAL’s Created
Pallet Plagues
Created
Scheduling Creates
priority and machine
Muller 227 set up
Kansa Set-up
Material is pulled
from Warehouse
Post press
production
Material Palletized
Pallet ShagedMail or Ship
Ship to customer
Mail Verified by
USPS
Loaded on USPS
Trucks
Deliver to SCF
Customer Service
Load on our trucks
USPS or Our
Trucks
Deliver to DDU for
Discounts
USPS to DDU
In-Home
ABC COMPANY PRODUCT FLOW – 1/22/15
Load on our Trucks
Deliver to SCF for
Discounts
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8. FISHBONE “ISHIKAWA” DIAGRAM (Example)
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9. Histogram / Pareto Principle (Example)
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0
2
4
6
8
10
12
14
16
18
Multi-vote Histogram

10. DEVELOP
• Phase III
o Develop a solution and a plan
• Output
o A solution for the problem
o Define Success
o Create metrics
o A plan for implementing the solution and subsidy plans
o Create Cost Management Plan
o Create a Risk Management Plan or FMEA
o Create a Communications Plan
o Create other PMBOK subsidy plans as required
• Steps
o Generate a list of promising solutions
o Select one solution
o Create WBS
o Develop an implementation plan
o Create a MS Project Gantt Chart
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11. EXECUTE
• PHASE IV
o Implement the plan, monitor results, adjust as needed
• Output
o Gain Organizational Commitment to plans
o An Executed Plan
o A record of Impact
o Earned Value Analysis
• Steps
o Gain sponsor commitment
o Execute the plan
o Assign additional resources as required
o Monitor the Impact
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12. Earned Value Management (Formula’s)
• Planned Value - % planned completion
• Earned Value - % complete x BAC
• Cost Variance - CV = EV-PC
• Schedule Variance - SV = EV-PV
• Cost Performance Index - CPI = EV/PV
• Schedule Performance Index - SPI = EV/PV
• Estimate at Completion - EAC = BAC/CPI
• Estimate to Completion - ETC = EAC-AC
• Variance at Completion - VAC = BAC-EAC
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13. SUSTAIN
•PHASE V
oEnsure a disciplined, repeatable process
oMust be able at all levels of OPERATIONAL LEADERSHIP - to sustain the “LCC
Process” in the current year, and years beyond.
•Output
oLessons Learned
oTeam Recognition
•Steps
oClose any Procurements
oEvaluate Mistake Proofing (Poka-Yoke)
oInstitute a Gemba Walk/Board as a SOP
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14. …operational expert committed to last change
Poka-yoke (Mistake-proof example)
Decision time to
use the process ?
Y
E
S