lean six sigma - ewh.ieee.org · 11/8/2018 · lean six sigma • lean manufacturing (lm) – a...
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Lean Six SigmaBrett Ellis PhD PE CSSBB
IEEE SeminarWells Conference Center
University of Maine Orono MaineNovember 8 2018
Brett D Ellis PhD PE CSSBBbull Assistant Professor Mechanical Engineering Technology University of Maine
bull BS in Mechanical Engineering ndash University of Houstonbull MS in Mechanical Engineering ndash NC State Universitybull PhD in Mechanical Engineering ndash Georgia Institute of Technologybull 21 years experience in Mechanical Engineering
ndash Primarily in materials and product development
bull 10 years experience at Southeastern Container Incndash Product Development Managerndash Commercialized numerous bottles preforms and finishes
ndash Reduced commercialization time from 15 years to as little as 21 daysndash Reduced mean bottle mass by ~7
Redesigned water bottlesLighter finishes (-13 g) Redesigned preforms (-07 g)
Lean Six Sigmabull Lean Manufacturing (LM) ndash a continuous improvement
methodology that seeks to understand value (ie what customers are willing to pay for) and eliminate wastes (iewhat customers are unwilling to pay for)
bull Six Sigma (6σ) ndash a continuous improvement methodology to reduce defects to extremely low levels
LEAN MANUFACTURING
ValueNon-Value Added (VNVA)
bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred
bull Non-Value Added Activity ndash Any activity that does not add value to the product or service
bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted
1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes
Defects ndash Non-conforming production
Overproduction ndash Producing too much
Transportation ndash Forklifts conveyors trucks
Waiting ndash Idle operators
Inventory ndash Parts WIP inventory supplies
Motion ndash Unnecessary motion eg walking
Processing ndash Burr removal reshaping inspection
DOTWIMP
7 Types of Muda (ie Wastes)
Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine
Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S
2 S3 S4 S5 S
5S
Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices
Chemical cabinet Before 5S Chemical cabinet After 5S
Continuous Flow Efficient amp Faster
Traditional BatchLayout
Continuous FlowLayout
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Brett D Ellis PhD PE CSSBBbull Assistant Professor Mechanical Engineering Technology University of Maine
bull BS in Mechanical Engineering ndash University of Houstonbull MS in Mechanical Engineering ndash NC State Universitybull PhD in Mechanical Engineering ndash Georgia Institute of Technologybull 21 years experience in Mechanical Engineering
ndash Primarily in materials and product development
bull 10 years experience at Southeastern Container Incndash Product Development Managerndash Commercialized numerous bottles preforms and finishes
ndash Reduced commercialization time from 15 years to as little as 21 daysndash Reduced mean bottle mass by ~7
Redesigned water bottlesLighter finishes (-13 g) Redesigned preforms (-07 g)
Lean Six Sigmabull Lean Manufacturing (LM) ndash a continuous improvement
methodology that seeks to understand value (ie what customers are willing to pay for) and eliminate wastes (iewhat customers are unwilling to pay for)
bull Six Sigma (6σ) ndash a continuous improvement methodology to reduce defects to extremely low levels
LEAN MANUFACTURING
ValueNon-Value Added (VNVA)
bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred
bull Non-Value Added Activity ndash Any activity that does not add value to the product or service
bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted
1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes
Defects ndash Non-conforming production
Overproduction ndash Producing too much
Transportation ndash Forklifts conveyors trucks
Waiting ndash Idle operators
Inventory ndash Parts WIP inventory supplies
Motion ndash Unnecessary motion eg walking
Processing ndash Burr removal reshaping inspection
DOTWIMP
7 Types of Muda (ie Wastes)
Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine
Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S
2 S3 S4 S5 S
5S
Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices
Chemical cabinet Before 5S Chemical cabinet After 5S
Continuous Flow Efficient amp Faster
Traditional BatchLayout
Continuous FlowLayout
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Lean Six Sigmabull Lean Manufacturing (LM) ndash a continuous improvement
methodology that seeks to understand value (ie what customers are willing to pay for) and eliminate wastes (iewhat customers are unwilling to pay for)
bull Six Sigma (6σ) ndash a continuous improvement methodology to reduce defects to extremely low levels
LEAN MANUFACTURING
ValueNon-Value Added (VNVA)
bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred
bull Non-Value Added Activity ndash Any activity that does not add value to the product or service
bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted
1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes
Defects ndash Non-conforming production
Overproduction ndash Producing too much
Transportation ndash Forklifts conveyors trucks
Waiting ndash Idle operators
Inventory ndash Parts WIP inventory supplies
Motion ndash Unnecessary motion eg walking
Processing ndash Burr removal reshaping inspection
DOTWIMP
7 Types of Muda (ie Wastes)
Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine
Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S
2 S3 S4 S5 S
5S
Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices
Chemical cabinet Before 5S Chemical cabinet After 5S
Continuous Flow Efficient amp Faster
Traditional BatchLayout
Continuous FlowLayout
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
LEAN MANUFACTURING
ValueNon-Value Added (VNVA)
bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred
bull Non-Value Added Activity ndash Any activity that does not add value to the product or service
bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted
1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes
Defects ndash Non-conforming production
Overproduction ndash Producing too much
Transportation ndash Forklifts conveyors trucks
Waiting ndash Idle operators
Inventory ndash Parts WIP inventory supplies
Motion ndash Unnecessary motion eg walking
Processing ndash Burr removal reshaping inspection
DOTWIMP
7 Types of Muda (ie Wastes)
Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine
Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S
2 S3 S4 S5 S
5S
Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices
Chemical cabinet Before 5S Chemical cabinet After 5S
Continuous Flow Efficient amp Faster
Traditional BatchLayout
Continuous FlowLayout
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
ValueNon-Value Added (VNVA)
bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred
bull Non-Value Added Activity ndash Any activity that does not add value to the product or service
bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted
1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes
Defects ndash Non-conforming production
Overproduction ndash Producing too much
Transportation ndash Forklifts conveyors trucks
Waiting ndash Idle operators
Inventory ndash Parts WIP inventory supplies
Motion ndash Unnecessary motion eg walking
Processing ndash Burr removal reshaping inspection
DOTWIMP
7 Types of Muda (ie Wastes)
Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine
Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S
2 S3 S4 S5 S
5S
Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices
Chemical cabinet Before 5S Chemical cabinet After 5S
Continuous Flow Efficient amp Faster
Traditional BatchLayout
Continuous FlowLayout
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Defects ndash Non-conforming production
Overproduction ndash Producing too much
Transportation ndash Forklifts conveyors trucks
Waiting ndash Idle operators
Inventory ndash Parts WIP inventory supplies
Motion ndash Unnecessary motion eg walking
Processing ndash Burr removal reshaping inspection
DOTWIMP
7 Types of Muda (ie Wastes)
Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine
Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S
2 S3 S4 S5 S
5S
Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices
Chemical cabinet Before 5S Chemical cabinet After 5S
Continuous Flow Efficient amp Faster
Traditional BatchLayout
Continuous FlowLayout
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine
Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S
2 S3 S4 S5 S
5S
Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices
Chemical cabinet Before 5S Chemical cabinet After 5S
Continuous Flow Efficient amp Faster
Traditional BatchLayout
Continuous FlowLayout
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Continuous Flow Efficient amp Faster
Traditional BatchLayout
Continuous FlowLayout
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Poke-Yoke Mistake Proofing
Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger
httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3
In-N-Out Burger trays wonrsquot fit in
trash can
Diesel and gas nozzles
Collision between cars and trains
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Lean Manufacturing Example
Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
SIX SIGMA
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low
levels
-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
Prob
abili
ty
Standard deviation σ
x_
+6σ( )2
1
1
Nii
x xN
σ =minus
=minus
sum
1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book
bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1
~1 defective Christmas light for ~500 houses2
Christmas lights
Not 6σ
2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Why is Six Sigma Importantbull Problem-solving approaches that employ only
theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other
factors eg operators measurement system atmospheric humidity interactions
ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically
ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper
bull Six Sigma addresses these shortcoming via a systematic empirical approach
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of
implementation
bull GE saved ~$12 billion in the first five years of implementation
bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland
LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
What is the Cost of Poor Quality
bull Prevention (0 ndash 5)ndash Capability studies training pilot
projects design reviews
bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw
materials inspecting final products
bull Failure (40 ndash 80)ndash Internal Repairs sorting failure
reviewsndash External Recalls warranty expenses
litigation Levels of Product Costs
Prevention
Appraisal
Failure(Internal amp External)
Quality Council of Indiana (2001) CSSBB Primer p III-62
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Why Does Variability Matterbull Money
-4 -3 -2 -1 0 1 2 3 4
xA_
LSL
egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza
-4 -3 -2 -1 0 1 2 3 4
xB_
Prob
abili
ty
Normalized Critical to Quality (CTQ) parameter
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
SAMPLE PROJECTS
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of
niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57
secbottlebull Process improvements
ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)
bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment
Originalprocess
1 Queue empty bottles
2 Move pot
3 Place funnels and fill
4 Replace pot
5 Return to counter
6 Queue filled bottlesImprovedprocess
1 Place 1 bottle in sink
2 Fill bottle via valve
3 Return filled bottle
6
45
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes
week each requiring ~233 mins
bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins
bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart
parking lotndash Reduced movement by transporting all components
in single trip
bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours
Thermoforming mold change
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Project Chemical Processingbull Background Research into biomedical applications of seaweed-
extracted polysaccharides is limited by the rate and efficiency of current extraction methods
bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process
bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting
systembull Results
ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95
reduction)ndash Successful processes increased from ~40 to 100
Re-usable centrifugal tube
Original centrifugal tube
Water bath mounting system
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-
Summarybull Lean Manufacturing seeks to decrease wastes amp add value
bull Six Sigma seeks to reduce variation and defects to near zero levels
bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development
ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau
Ref Thoreau (1910) Walden p 117
Brett Ellis brettellismaineedu
- Lean Six Sigma
- Brett D Ellis PhD PE CSSBB
- Lean Six Sigma
- Lean manufacturing
- ValueNon-Value Added (VNVA)
- 7 Types of Muda (ie Wastes)
- 5S
- Continuous Flow Efficient amp Faster
- Poke-Yoke Mistake Proofing
- Lean Manufacturing Example
- Six Sigma
- Six Sigma 6σ
- Why is Six Sigma Important
- Why is Six Sigma Important
- What is the Cost of Poor Quality
- Why Does Variability Matter
- Sample projects
- Project Filling Bottles
- Project Reduce Mold Change Times
- Project Chemical Processing
- Summary
-