LSSG Green Belt Training Introduction to Lean Six
LSSG Green Belt Training Introduction to Lean Six Sigma Intro to LSS 1
Who is Responsible for LSS? Defining Roles and Responsibilities CHAMPION Senior manager responsible for overall success of project. MASTER BLACK BELT Train/coach/mentor BBs, monitor progress. BLACK BELT Full-time LSS employees, Lead, track project, mentor GBs. GREEN BELT Work part-time on LSS in their work areas. OTHER BELTS Team Members, Data Collectors, Subject Matter Experts (SMEs). Intro to LSS 2
Deming’s 14 Points W. Edwards Deming (1900 -1993) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Create constancy of purpose for improvement Adopt a new philosophy Cease dependence on mass inspection Do not award business on price alone Work continually on the system of production and service Institute modern methods of training Institute modern methods of supervision of workers Drive out fear Break down barriers between departments Eliminate slogans, exhortations, targets for the work force Eliminate numerical quotas Remove barriers preventing pride of workmanship Institute a vigorous program of education and retraining Take action to accomplish the transformation Intro to LSS 3
Sigma ( ) vs Sigma Level = Standard Deviation l a measure of variation around the average Sigma Level = 1/2 the number of standard deviations ( ) that will fit between the specification limits when the process is centered Customer Specifications = 8/2 = 4 = 12/2 = 6 Sigma level is also a measure of the number of defects per opportunity produced by a process. Intro to LSS 4
Six Sigma Improvement Methods Six Sigma accommodates both Improvement and Reengineering Define Measure Analyze Improve Design Control Validate Intro to LSS 5
Six Sigma Improvement Role of Tollgates l Ensure Sequence l l l Measure Analyze Enable Communication l l Define Obtain formal approval to move to the next DMAIC phase Prevent team from skipping steps Provide management with project updates at each level Allow Charter Updates l Make modifications to project scope Intro to LSS Improve Design Control Verify 6
DMAIC Six Sigma - Define Objectives l Identify Customers l Complete Charter l Understand Process Control Improve Analyze Define Measure Intro to LSS Tools Charter, VOC, VSM, CTQ SIPOC, Scorecards 7
DMAIC Six Sigma - Measure Objectives l Identify Inputs and Outputs l Measure Process Capability l Revise Charter Control Improve Analyze Define Measure Intro to LSS Tools Brainstorming, MSA, Walkthrough, C&E, 5 S, KPOV, KPIVs, RTY, Benchmarking 8
DMAIC Six Sigma - Analyze Where are the key leverage points for driving breakthrough performance? Objectives l Determine Variation Sources l Prioritize Key Outputs and Inputs l Revise Project Benefits Control Improve Analyze Define Measure Intro to LSS Tools Fishbone Diagram, Pareto Chart, Process Capability, Control Charts, Layout and Process Flow Analysis FMEA, Statistical Analyses 9
DMAIC Six Sigma - Improve How do we get there? Objectives l Develop Potential Solutions l Develop Future State l Evaluate and Mitigate Risk Control Improve Analyze Define Measure Intro to LSS Tools Kaizen Event, Contingency Planning, Pilot, DOE, Optimization. 10
DMAIC Six Sigma - Control How Do We Keep the Gains? Objectives l Implement Controls l Standardize l Evaluate Benefit Control Improve Analyze Define Tools Standardization, Training, Visual Aids, Mistake Proofing, Documenting Benefits Measure Intro to LSS 11
DMAIC Six Sigma - Design How do we create and implement a new process that will delight the customer and provide outstanding business results? Objectives Verify/ Validate Design l l l Analyze Design Product/Process Evaluate Product/Process Structure Evaluate Risk/Benefit Define Measure Intro to LSS 12
DMAIC Six Sigma - Verify How do we determine if the new process is successful? Verify/ Validate Objectives l Beta test l Plan Implementation l Implement Solution Design Analyze Define Measure Intro to LSS 13
What is Lean? JIT Delivery Elimination of Non. Value Add Activity Visual Management Continuous Flow Genuine Focus on the Customer Pull Culture for Lean Increase Offering/Decrease Changeover Kaizen Events Lean Tools, Methods and Measures LEAN - Like water running downstream - more speed with less effort! Intro to LSS 14
The Lean Six Sigma Approach Define Scope / Opportunity Current State Future State Gap Process cleanup 5 S and other Lean Tools Yes No Known Solution 6 Sigma Project Lean Project Yes DMADV Intro to LSS New Design? No DMAIC 15
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