Transcript: During the phase of Define, all customers’ needs are taken into consideration and there is an established a connection between the suppliers, input, process of manufacturing, output and customers. This phase enables to understand the main customers’ demands. Define Analyze Despite the importance and complexity of implementing of Six Sigma in the manufacturing organization, there are still main hurdles in its successful implementation Among other shortcomings of Lean manufacturing and Six Sigma is that Lean manufacturing is expensive in its implementation, questionable flexible, while the Six Sigma is structured. The most, however, disadvantage of Six Sigma is that as it is applied to all production and planning processes, it can develop rigidity and bureaucracy and thus cause delays and stifle creativity in the manufacturing. The most important is the involvement of major changes to the workplace, where for instance the Lean implementations are not successful since management underestimated the time and efforts for implementation. In addition, Lean and Six Sigma can provide conflicting answers and then system needs to solve such differences and address then situations where conflicting areas will be championed. Thus, Six Sigma is not appropriate for resolving small problems with the great numbers of variables. Lean techniques are more effective in solving such small issues. While Lean Six Sigma represents the management approach that provides improvement and drives innovation, it also decreases the process variation. During the measure phase, it is necessary to gather quantities and qualitative data in order to obtain accurate current situation. Whether the gathered data is gathered to be used, an organization may start change the elimination waste process and issues connected with the methodology. The Analysis phase enables organization to use numerous analytical technologies to understand the cause of the problem and waste. Nicole Mills HRM 420 Corporate Training and Development Shortcomings Control The phase of Control manages implementation of improvements. It manages constant process and reports on the variation if they occur. During this phase Six Sigma uses statistical process control. With all the positive aspects of Lean Six Sigma approach, the application of this methodology will be more suitable for bigger companies and focus on the results and not on the implementation and the tools chosen for needs, goals and organizational structure. Six Sigma has a positive impact on the waste reduction and thus operational efficiency. Despite limitations of the techniques, Six Sigma is able to provide an organizational structure not seen in the past. Lean Six Sigma can be broken up into phases such as… The Five'S tool is the most often used in the Lean manufacturing, which takes into account concerns with the cultural change, systematic and standardized processes normal routine. Five S’s Sort Store Shine Standardize Sustain lean manufacturing. The tools are the Data collection and analysis tools, Data collection tools and techniques and Seven management tools. The use of lean tools and techniques explain the leveraged by Six Sigma techniques areas. Measure Control The Improve phase means that both Six Sigma and Lean manufacturing can be changed and particular resolution is formed on the basis of defects and waste, which were analyzed during the previous phase. The phase of Improve is aimed to implement a resolution in manufacturing method and ensure the elimination defects and waste. Improve Define Best practices of Six Sigma and Lean manufacturing are aimed to improve company’s performance. Organized data in forms of diagrams, structure trees and charts will allow the company to ensure the DMAIC processes to be conducted in accordance with the company’s demands. LEAN SIX SIGMA Measure Lean Six Sigma Methodology Analysis Practices The main idea of Lean and Six Sigma to create value based on the final requirements of a customer, Lean Six Sigma’s importance cannot be underestimated. Growth of world manufacturing has created a need to measure elimination of waste through use of tools, techniques and methodology that would enable business to manage... Overproduction Defects in products Waiting time Inventory other connected with the production processes. The central idea that stands behind the Six Sigma is to improve the quality of the process by removing the defects of the products in manufacturing. Improve Tools LEAN SIX SIGMA
Transcript: collect data from existing processes and identify the critical variables. The essence of Lean Six Sigma optimize outputs & implement the solution. In a nutshell ! evaluate and document the current state of process Lean = Eliminate Waste! Lean Six Sigma identifying metrics, objectives & timelines. Methodology Phases planning & executing the appropriate designed experiments. measure the results & ensure ongoing process controls are maintained. This methodology forces us to make improvements through data-driven decision making, not intuition. Identifying your biggest problems; Assigning your best people to fix these problems; Providing them with all of the tools, resources and support needed; Guaranteeing them totally uninterrupted time to focus on permanently eliminating these problems! DEFINE MEASURE ANALYZE IMPROVE CONTROL REALIZE
Transcript: Future standard at 99.9997% perfection 3.4 defects per million opportunities a historical standard at 99.73% perfection this means 66,800 defects per million opportunities D:Design 1980's Mathematically: at 6 sigma: C: Control First success Design the initial process that will provide stronger support, problem preventing and solving measures Problem Solve M: Measure After implementation, Motorola documented more than $16 billion in savings V: Verify Collect the Data Real life example: Ex. This involves looking at the process and determining the errors that have occurred from start to finish on each account in the data History of Lean Six Sigma Based remaking a product on it's sigma level. 3 sigma standard deviations or below then the product would not meet quality standards Six Sigma: the elimination of waste and the enhancement of workflow CEO Bob Galvin challenged employees to improve their quality by 10 times over 5 years Ex. -Account Review -Working with your team that handles specific accounts -Process Review/Process Flows -A forum for your team to provide these issues Implement Solutions This is when you find the issues that are creating the biggest problems 3 sigma vs 6 sigma The Story 200,000 wrong drug prescriptions every year a small group of experienced professionals input from different departments to ensure output is inclusive Bill Smith an engineer at Motorola Company Be Prepared First time term used Lean Six Sigma A: Analyze The first three are the same: D:Define M:Measure A:Analyze D: Define Brainstorm for other reasonable resolutions Have a plan for change management Prepare the staff Build a good team to implement Motorola was challenged by a competitor that proved to have 1/20th of the errors Once implemented, need to identify the errors and ensure they are eliminated early on at 3 sigma: Stimulate Process Make sure the team is aware of the adjustments Manage any and all obstacles that arise 1 incorrect drug prescription every 25 years What is Lean Six Simga? The first Six Sigma Quality Review Program was launched by Smith and Mikel Harry in 1987 Walter Stewhart DMAIC Sigma is Greek letter used to represent standard deviation To have a plan for decreasing our cost and the amount of work required by eliminating waste and improving efficiency within every process in our company Questions Perform statistical tests against your standards to find where the improvement can be made First use as a quality measurement Building the Right Team Improving daily by eliminating waste Lean: Ex. -MAPKEYs - Hammer Report/KPIs Can use these industry standards to know how you compare to others a management methodology to improve quality and consistency in processes In a business: a process used to perfect business processes already in place Used to create and perfect new products and services DMADV "Three sigma to six sigma divides the ordinary from the extraordinary" - Walter Stewhart Use this data and measure against a standard The End Result Ex. - Send out memos - Have an updated SOP/SOW prepared I: Improve by using sigma we can measure the deviations we are from the average within a process more deviations = more defective products or lower efficiency the problems are the defect in a product that cost our organization money How can we use Lean Six Sigma? Find the Error Define a goal
Transcript: 1. Transportation 2. Inventory 3. Motion 5. Over production 6. Over processing 7. Defects 8. Skills By understanding of all aspects of the Lean Six Sigma Methodology 4. Waiting Reduce defects critical to quality characteristics Provided through belt based training systems Black Belt Certification 8 Kinds of Waste How do we get to Black Belt Certification? In a nutshell...it's a collaborative effort to remove waste Define, Measure, Analyze, Improve and Control LEAN SIX SIGMA DAMAIC What is lean six sigma? The Core of Lean Six Sigma Training for Lean Six
Transcript: About Me Six Sigma as a methodology Understanding Lean Six Sigma as a Management System Six Sigma- Improve process by reducing variation Six Sigma as a Metric Introduction to Six Sigma Presently working as consultant Training Mentoring and facilitation About Me Origin of Six Sigma Understanding Six Sigma Understanding Lean Q & A Management System Methodology Metric Lean Six Sigma What is Six Sigma? Lean - Increase speed by eliminating waste Lean Six Sigma Integration Six Sigma is a Delivered around 200 + hours of training Mentored around 50 + projects Metal Mining Heavy Machinery Manufacturing Pharma and IT Defects Over-production Transportation Waiting Inventory Motion Over-processing Agenda Bachelors in Mechanical Engineering Worked in IISc Masters in Industrial Engineering and Management Certified Lean Six Sigma Green Belt and Trained Lean Six Sigma Black Belt Road map Types of waste
Transcript: 5s 5 Why 1. Transportation 2. Inventory 3. Motion 4. Waiting 5. Overproduction 6. Over-processing 7. Defects 8. Under utilization of employees Sort, Straighten, Shine, Standardize, Sustain Shannon Smith, Cameron Doyle Jose Villa-Cruz Lean Six Sigma For Dummies Cheat Sheet - For Dummies . (n.d.). How-To Help and Videos - For Dummies. Retrieved March 4, 2013 Corsention, D.T. (1993) Employee involvement. FBI Law Enforcement Bulletin, 62(11),10. Tanner, M. (Director) (2013, January 22). 5S and Visual Management . Process Improvement. Lecture. The Ohio State University , Columbus. Lean Six Sigma Commitment is Key Loftus, R., Dobb, C., & Lawson, L. (2011). Employee engagement. MLO: Medical Laboratory Observer, 43(3), 34. Change is Risky Lean Six Sigma = CHANGE!! Tanner, M. (Director) (2013, January 22). 5S and Visual Management . Process Improvement. Lecture. The Ohio State University , Columbus. Corsention, D.T. (1993) Employee involvement. FBI Law Enforcement Bulletin, 62(11),10. Visual Controls Lean Six Sigma Green Belt Course. (n.d.). MoreSteam University. Retrieved March 3, 2013 Lean Six Sigma Green Belt Course. (n.d.). MoreSteam University. Retrieved March 3, 2013. Spaghetti Diagrams Liker, J. K., & Meier, D. (2006). The Toyota Way Fieldbook: a practical guide for implementing Toyota's 4Ps. New York: McGraw-Hill 8 Wastes: T.I.M.W.O.O.D +U DMAIC Goals are the same Lean Tools Employee Engagement
Transcript: Product Overview Who we are Who we are General Who we are Light Guide Systems Classic Ops Solutions patented projection system and latest augmented reality technology. Eliminate operator reliance on printed work instructions, computer screens or memory for assembly guidance through the use of intelligent VDFs. Built on the HP Sprout platforms, offers augmented reality in a smaller form factor. Reduces errors by projecting directly onto a predefined operating “canvas” designed for small parts while providing audio and visual prompts, guidance, pacing and direction. AccuKit What's done What needs work Light Guide Systems Pro Products Products Light Guide Systems Classic Ops Solutions patented projection system and latest augmented reality technology. Eliminate operator reliance on printed work instructions, computer screens or memory for assembly guidance through the use of intelligent VDFs. Built on the HP Sprout platforms, offers augmented reality in a smaller form factor. Reduces errors by projecting directly onto a predefined operating “canvas” designed for small parts while providing audio and visual prompts, guidance, pacing and direction. AccuKit Our kitting solution replaces and improves upon hard-wired kitting solutions like pick-to-voice and pick-to-light. AccuKit guides kitting personnel to efficient and accurate results. Our solution has the highest adoption rate in the industry. Our simple to use software makes adjustment to racks simple and cost effective. Light Guide Systems Pro Our Team Our Team Our Customers Our Customers Our Solutions Our solutions Our solutions solve complex manufacturing problems, by bridging together the best in human intelligence with machine intelligence. Using augmented reality we aide our customers in mistake proofing processes that previously could not be using traditional means. Mistake-proofing Mistake-proofing Error-proofing Error-proofing When safety or product quality cannot be risked, we utilize our patented, projector-based augmented reality solution coupled with 3D vision and other tools to ensure processes are being done right the first time, every time! Revolutionary training solution that: Drastically reduces operator learning curve Improves operator productivity and quality Standardizes training across all shifts (reduces variation) Reduces the cost to train and retrain employees Training Training Our proprietary kitting solution makes setting up and maintaining kitting areas fast, easy and cost-effective. Our solution provides highly-accurate kitting without being burdensome on your associates: Monitor-based or projector guidance Simple, intuitive drag and drop user interface Changing bin locations or racks requires no wiring Long term cost of ownership far superior to pick-to-light, pick-to-voice technology Kitting Kitting Solution Matrix Solution Matrix Light Guide Systems Classic Ops Solutions patented projection system and latest augmented reality technology. Eliminate operator reliance on printed work instructions, computer screens or memory for assembly guidance through the use of intelligent VDFs. Built on the HP Sprout platforms, offers augmented reality in a smaller form factor. Reduces errors by projecting directly onto a predefined operating “canvas” designed for small parts while providing audio and visual prompts, guidance, pacing and direction. AccuKit What's done What needs work Light Guide Systems Pro Light Guide Systems Classic Light Guide Systems Classic Fully customizable systems for any application Multiple projector options (LED, Bulb Base, High Resolutions, etc.) Scalable to interface with additional projectors, cameras, torque guns, mounting structure, etc. Multiple products / programs can be ran at a single work station Collect and store real-time data for analytical and quality studies Compatible to integrate directly to MES and PLC interfaces Easily programmable, intuitive and user friendly software Light Guide Systems Pro Light Guide Systems Pro HP Pro / Light Guide Systems Platform Integrated projector/web cam/touch HMI/touch pad Capability to add additional projector and vision camera Plug and Play setup-No assembly required Works on any tabletop Large, HD monitor for detailed images Provides light guidance in a 12” x 16” canvas footprint Same work instruction authoring software as Light Guide Systems Classic Traditional countermeasures Lean Six Sigma Tools Lean Six Sigma Tools Lean Fundamentals Lean Six Sigma Fundamentals Elimination of waste Reduction of variation Stable, predictable processes Standardization Quality at the source Visual feedback Daily continuous improvement 8 Wastes Defects Overproduction Waiting Non-utilized talent Transportation Inventory Motion Excess processing 1. A step that advances the part closer to it's finished state. 2. The customer must be willing to pay for this activity. 3. Must be done right the first time. Definition of Value Added 1. Error due to misunderstanding 2. Errors due to lack of 1.
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