Introduction to Lean Six Sigma Learning Outline What

Introduction to Lean Six Sigma

Learning Outline • • What is Six Sigma • Why DMAIC is different from other Quality The Six Sigma Philosophy Models Brief History of Six Sigma • Six Sigma Certifications DMAIC Methodology • Six Sigma Roles – Define • Recap – Measure – Analyze – Improve – Control 2

What is Six Sigma (6σ) Six Sigma (6σ ( ) represents the level of quality when the defects are decreased to 3. 4 in 1, 000 million opportunities Few Examples Out of 1, 000 parcels a courier company delivers apprx. 999, 996 parcels on time while approx only 4 are delayed ! Out of 1, 000 service hours a telecom company’s service are up 999, 996 hours while experiencing the down time of only 4 hours! 3

What is Six Sigma (6σ) • Have you noticed the large sample size – i. e. 1, 000 ? • What if we don’t have 1, 000 samples / opportunities …… well lets run few quick tests 1, 000 Opportunities 25, 000 Opportunities 150 Opportunities 4

Six Sigma Philosophy The quality of the product /service depends on the process used to develop that product/service Six Sigma : § Improves the underlying business process § Is Customer focused § Uses statistical tools 5

Brief History of Six Sigma Motorola , Citibank , general Electric and Allied Signals were the early adapter of Six Sigma Bill Smith in 1986 standardized Bill Cohen – an the Six Sigma engineer in i. e. 1 Mil Motorola Opportunities coined the term Six Sigma for In 1818 Johann Carl the firs time Gaussian introduces concept of Normal Distribution – Motorola reported $ 16 Billion savings due the basis of to Six Sigma Adoption Six Sigma 6

DMAIC Methodology DMAIC is abbreviation of the 5 key steps required to run Six Sigma projects Define Control Measure DMAIC Improve Analyze 7

Define Phase – Steps & Tools Develop Charter and Business Case SIPOC Process Mapping Map Existing Processes Define Value Stream Mapping Spaghetti Chart VOC Collect Voice of Customer Specify CTQ Requirements Step Affinity Diagram CTQ Tree Tools 8

Measure Phase – Steps & Tools Measure Step Tools Measure CTQs CTQ Tree Determine Process Stability Statistical Process Control Data & Data Collection Data collection Check Sheet Validate Measurement System R& R gauge Establish Process Capability Calculating Cp & Cpk Histogram 9

Analyze Phase – Steps & Tools 5 -Whys Identify Root Causes Analyze Quantify Root Causes Fishbone Diagram FMEA Tools Scatter Plot Verify Root Causes Step Tools Correlation and Regressions Analysis 10

Improve Phase – Steps & Tools Generate and Select Solutions Improve Deign Solutions Brainstorming Cost-Benefit Analysis ROI Prioritize and Select Solutions Pilot Solutions Implementing Solutions Step A 3 Report Tools 11

Control Phase – Steps & Tools Develop Control Plan Develop Control Apply Statistical Process Control Transfer Required Tools to Process Owners Perform Financial Evaluation and Audit Step Tools 12

How is DMAIC Different Cohesive Process Based Quantitative Stakeholder improvement Project Based Comprehensive DMAIC Customer Centric 13

Six Sigma Certification MASTER BLACK BELT GREEN BELT YELLOW BELT WHITE BELT 14

Six Sigma Roles Executive Management / Sponsors MASTER BLACK BELT GREEN BELT YELLOW BELT WHITE BELT 15

Recap Six Sigma : § Improves the underlying business process § Is Customer focused § Uses statistical tools DMAIC is Six Sigma Methodology with following phases : § Define § Measure § Analyze § Improve § Control 16

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