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Lean Six Sigma (Extended Version)
Transcript of Lean Six Sigma (Extended Version)
Six Sigma is eliminating variation. These techniques can be used together
to improve inefficiencies and lower the cost to do business.
This adds value to the customer. Customers,
Who are they? BELTS:
- Master Black What is value? Value is what the customer is willing to pay for.
It can be in the form of providing a product or service. Lean is an approach that requires working together
to continuously improve processes. It requires a commitment
from everyone. Mistake Proofing (Poka Yoke).... 'Quality is everyone's responsibility'
- W Edwards Deming "It is not the EMPLOYER who pays the wages.
He only handles the money.
It is the PRODUCT that pays the wages."
~Henry Ford Six Sigma follows the DMAIC approach.... Lean follows the PDCA model... Tools Before After Seek to Identify the 8 Deadly Forms of Waste WAITING "Time waste differs from material waste in that there can be no salvage. The easiest of all wastes and the hardest to correct is the waste of time, because wasted time does not litter the floor like wasted material."
- Henry Ford Transportation Motion Over production Extra Processing INVENTORY defects, Inspection
and rework Underutilized talents Kaizen Event Kai - to work together
Zen - to improve We have a new facility...how should we lay it out? Thank YOU!! Your Lean Six Sigma Team:
Cliff Edwards Extra Processing Extra Processing Defects cause rework. Rework can double, if not triple the cost
of performing a task that should have been done right the first time.
Not all defects are caught with inspection, some the customer finds.
Those can damage our reputation, which can lead to damaging our profits. The most obvious is the external customer:
The person buying the goods or service
for DynCorp, Department of State is our customer. However, we are all each other's internal customer:
The pilot is a customer of the mechanic
The mechanic is a customer of production control
Production control is the customer of the Buyer... Lean Six Sigma uses many Tools to document your process including:
SIPOC Diagram - supplier, inputs, process, outputs, customer
Value Stream Map - this is where you look for the waste
Process Map - shows the different departments involved and steps
Spaghetti Diagrams - used to show all of the movement in a layout Tools to quantify risk:
FMEA: Failure Modes Effect Analysis
Rolled Throughput Yield
Gage R& R (Repeatability & Reproducility) The 5 Why Method
Why? Cause and Effect Diagrams
(Fishbone Diagrams) Questions? In Summary...
Lean is a way of: Thinking
Learning It is a continuous journey Office Waste 6S remove items that are not needed
a place for everything and everything has its place
cleanliness; be proud of your work area
keep your hard work from unraveling
pay attention, wear protective gear, pay attention Sort
Set in order