Introduction to Lean and Six Sigma Module One

Introduction to Lean and Six Sigma

Module One

Names of Lean • You may hear the following terms used: • Lean Manufacturing • Cellular Manufacturing • One-piece flow • Just-in-time production Originally known and still known today as: Toyota Production System

What does a lean manufacturing culture look like…?

Lean Culture • • The People and Teamwork • Team members are engaged and believe in the process • Managers help grow team members Respect for others • • ALL employees respect and value the viewpoints of their fellow team members Engaging and accountability • Identify problems • Lean how to problem solve • A lean manufacturing culture is a everyone’s responsibility. Not just management!

Lean Culture • Change • Adapt to constant changes • Engage in Continuous improvement – • • The iterative process of changing the way things are done or materials used, in a small scale or large scale, to produce a better outcome. Training • Extensive training for skilled job tasks • Learning to be a skillful problem solver • Cross training amongst team members • Creating flexibility to move members to different job tasks

Lean Building Blocks Continuous Improvement/Kaizen Pull Heijun Cells/ One Piece (Kanba ka TPM Flow n) Set up Mistake JIT Quality at the Reductio POU proofing (poka source S andon Proble yoke) n Batch Team m Standard Work Reductio Solvin s n g Visual 5 S System Plant Layout LE 101 Principles — 2/02 v 1 Value Stream Mappi ng 7

Lead Time required to take a product from raw material to finished goods Customers often demand short lead times Shorter lead time= more profit

Not all lead time adds value to the product… Team Center Mill #1 Non Value Added Activity Mill #2 Mill #3 Raw Material Inspection Storage Value Added Activity Lathe In Process Inspection Shipping Finish Machining Ship ORDER Value-Added Time: Time on shop floor: Minutes Weeks CASH

Lead Time = Value Processing Time + Non-value Processing time wastes To decrease Lead time, we decrease Non-value Processing time! http: //www. slideshare. net/naeembhai/toyota-production-system-7 -muda

What is six sigma…?

Six Sigma Six sigma is a problem methodology that helps enhance business and organizational operations. It can be defined in a number of ways: Quality level = 3. 4 defects per 1, 000 Rate of improvement of 70% or better Six sigma initiative is taken on to make bottom line breakthrough change

Sigma Examples 99% or 3. 8 Sigma 20, 000 lost articles of mail per hour Unsafe drinking water for almost 15 minutes per day 5, 000 incorrect surgical operations per week Two short or long landings at most major airports each day 200, 000 wrong drug prescriptions each year No electricity for almost seven hours each month 99. 99966% or 6 Sigma • Seven articles of mail lost per hour • One unsafe minute every seven months • 1. 7 incorrect operations per week • One short or long landing every five years • 68 wrong prescriptions each year • One hour without electricity every 34 years

Module 1: Knowledge Check-off 1. Lead time= ___________+___________ 2. Name 5 Lean Manufacturing “building blocks”. 3. Whose responsibility is it to implement a lean manufacturing culture ?

End Of Module 1