Analyze tollgate and garment defect exercise

Learning objectives

• Assemble the Analyze tollgate evidence pack.
• Answer gate questions with process and data evidence.
• Bridge confirmed Xs to Improve experimentation.

Required evidence

• Cause inventory, fishbone, Five Whys, C&E matrix, FMEA.
• Stratified graphs, chosen tests and models with CIs.
• Assumptions, mechanism explanation, alternative-explanation check.
• Evidence table and prioritised vital Xs.

Garment-factory example

Measurement-repair variation is explained by tape condition, inspector and fabric construction; controlled tape replacement plus calibrated fixtures deliver a testable Improve pilot.

Method

1. Compile the pack against the checklist.
2. Present with sponsor and process owner.
3. Log gaps that require additional data or pilot design.
4. Approve the vital few Xs for Improve.

Common mistakes

• Equating p < 0.05 with root-cause proof.
• Proposing solutions before cause confirmation.