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The Lean Six Sigma System
- Main Goal
- Maximize shareholder value
- How
- Achieving the fastest rate of improvement in
- Customer Satisfaction, Cost, Quality,
Process Speed, Invested Capital
- Customer Satisfaction, Cost, Quality,
Process Speed, Invested Capital
- Achieving the fastest rate of improvement in
- How
- Maximize shareholder value
- Lean Six Sigma
- Lean manufacturing tools
increase process speed and reduce
process waste. Six Sigma quality
tools to reduce process variation
and eliminate product defects
- Lean manufacturing tools
increase process speed and reduce
process waste. Six Sigma quality
tools to reduce process variation
and eliminate product defects
- Six Sigma: The Power of a
Quality Culture
- Goal
- Create a quality management system to measure
process capability and to improve it to
near-perfection
- Create a quality management system to measure
process capability and to improve it to
near-perfection
- The Quality Culture
- Customer centric, finanalcial results, management
engagement, resource commitment (1-3% staff), excecution
infrestructure
- Metrics
- Potential Process Capability Index (Cp)
- Process variation vs. Quality specifications,
it must be larger than 1.33
- Process variation vs. Quality specifications,
it must be larger than 1.33
- Real Process Capability
Index (Cpk)
- Process distribution vs. Quality specifications,
it must be larger than 1.00
- Process distribution vs. Quality specifications,
it must be larger than 1.00
- Potential Process Capability Index (Cp)
- Metrics
- Customer centric, finanalcial results, management
engagement, resource commitment (1-3% staff), excecution
infrestructure
- Goal
- Process and Improvement Tools
- Step 1: DEFINE
- Step 2: MEASURE
- Step 3: ANALYZE
- Step 4: IMPROVE
- Step 5: CONTROL
- Develop control plan, monitor
performance, and mistake-proof
process
- TOOLS
- Control plan, statistical process
control, Poka-Yoke devices, and
process documentation
- Control plan, statistical process
control, Poka-Yoke devices, and
process documentation
- TOOLS
- Develop control plan, monitor
performance, and mistake-proof
process
- Generate ideas for product and process
design, conduct experiments, create straw
models (prototypes), develop implementation
plans, and validate improvements
- TOOLS
- Design of experiments,
total productive
maintenance, SMED, flow
manufacturing, and
jidoka / autonomation
- Design of experiments,
total productive
maintenance, SMED, flow
manufacturing, and
jidoka / autonomation
- TOOLS
- Step 5: CONTROL
- Determine process capability
and speed, and determine
dources of variation and cycle
time bottlenecks
- TOOLS
- Statistical process control, process mapping /
arrow diagram, standard operations analysis, and
DFMEA /PFMEA
- Statistical process control, process mapping /
arrow diagram, standard operations analysis, and
DFMEA /PFMEA
- TOOLS
- Step 4: IMPROVE
- Define current state, confirm
project objectives, and collect
and display data
- TOOLS
- Lean Six Sigma diagnostic,
process mapping, statistical
process control (7H / 7M), and
MSA
- Lean Six Sigma diagnostic,
process mapping, statistical
process control (7H / 7M), and
MSA
- TOOLS
- Step 3: ANALYZE
- Identify black belt and team
resources, prepare team
charter, and obtain project
approval
- TOOLS
- Project management, VA /
VE, and financial analysis
- Project management, VA /
VE, and financial analysis
- TOOLS
- Step 2: MEASURE
- Step 1: DEFINE
- The Speed of Lean Manufacturing
- Goal
- Identify the “time traps” injected by fewer than 20% of the
workstations that cause 80% of the delays and eliminate
them
- Metrics
- Process Cycle Efficiency > 25%
- Value-Added Time, and Total Lead Time
- Value-Added Time, and Total Lead Time
- Sources of Waste Reduction
- Shorter lead time, less inventories, less material
handling, fewer customer complaints, and less scrap
and rework
- Shorter lead time, less inventories, less material
handling, fewer customer complaints, and less scrap
and rework
- Process Cycle Efficiency > 25%
- Metrics
- Identify the “time traps” injected by fewer than 20% of the
workstations that cause 80% of the delays and eliminate
them
- Goal