lean six sigma green belt training part 2

Lean Six Sigma – Green Belt Workshop

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Welcome

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What is Six Sigma?

“Sigma” is a letter from the Greek Alphabet

One Hour Of Unsafe Drinking Water Every MonthTwo Unsafe Plane Landings Per Day At O’Hare International Airport In Chicago16,000 Pieces Of Mail Lost By The U.S. Postal Service Every Hour500 Incorrect Surgical Operations Each Week50 Newborn Babies Dropped At Birth By Doctors Each Day22,000 Checks Deducted From The Wrong Bank Accounts Each Hour32,000 Missed Heartbeats Per Person, Per Year

If 99.9% is a good Quality : Then even in a country like USA, it Would Have…

Which one is good : 60%, 80%, 90%, 95%, 99%,

99.9% Correct

Which one is good : 60%, 80%, 90%, 95%, 99%, 99.9% Correct

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What is Six Sigma?

Six Sigma thinking: All processes can be Defined, Measured, Analyzed, and Improved and Controlled(phases of Six Sigma). Collection of above phases is popularly known as DMAIC. Any process has inputs (x),and delivers outputs (y). Controlling inputs will control output. This is y=f(x) thinking.

Process: Systematic Approach to improving processes and thereby Reducing Defects which affect What is Important to the Customer & To the Business

Six Sigma as set of tools: Contains qualitative and quantitative tools which Six Sigma practitioners use todrive improvements. Examples include Control charts, FMEA, process mapping, etc.

Metric: Six Sigma Quality means 3.4 defects in 1 million opportunities or a process with 99.99966% RolledThroughput Yield.

Six Sigma: It is the standard deviation of a process metric

Sigma Defects Per Million Success Rate Type of Organization6s 3.4 99.99% World Class5s 233 99.97% Competitive Class4s 6210 99.37% Competitive Class3s 66807 93.31% Average Class2s 3,08,537 69.14% Below Average Class

1s 697,672 30.23% Bad Class

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Meaning of Six Sigma?

• The term “sigma” is used to designate the distribution or spread about themean (average) of any process or procedure.

• For a process, the sigma capability (z-value) is a metric that indicates how wellthat process is performing. The higher the sigma capability, the better. Sigmacapability measures the capability of the process to produce defect-freeoutputs. A defect is anything that results in customer dissatisfaction.

What is it based on?Customer .....Anyone Who ReceivesProduct, Service, or Information

Opportunity .....Every Chance to Do SomethingEither “Right” or “Wrong”

Successes Vs. Defects .....Every Result of an Opportunity Either Meetsthe Customer Specification or it Doesn’t

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Goal of Six Sigma & Strategy

Six Sigma Strategy

• Know What’s Important to the Customer• Reduce Defects• Reduce Variation• Center Around Target

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Six Sigma Y= f(x) thinking

SIX SIGMA GREEN BELT- National Institute of Quality Certification. NIQC’s Restricted document. All rights reserved. This document cannot be Copied, Re-distributed, Transmitted or Printed without the written permission of [email protected]

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Six Sigma Roadmap

• Six Sigma Breakthrough Strategy1. Select CTQ Characteristic2. Define Performance Standards3. Validate Measurement System4. Establish Product Capability5. Define Performance Objectives6. Identify Variation Sources7. Screen Potential Causes8. Discover Variable Relationships9. Establish Operating Tolerances10. Validate Measurement System11. Determine Process Capability12. Implement Process Controls

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Green Belt as a Change Agent

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Roadblock for Six Sigma Implementation

Six Sigma is too statistical Individual has fear of change. Why should I change?No co-operation of employeeWrong team member or selection

For all this, we need to make them realize that they wouldn’t be penalized for their mistake. We should fosterthem with Move ahead approach. Show mutual benefit to stakeholders. MBB need to ensure all employees asconvinced not forced.No use of force tactics for employee supportWe need to choose team member based on their capacity, capability, ability & willingness. We should not haveduplicate skill set in team.

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Change Roadblock

Looking at his curve, which area you would like to focusfirst?Every organization or team split into 15% Supportive, 70% Neutral and 15% Resistant:-Don’t bother about 15% Supportive as they would support change anywaysDon’t bother about 15% Resistant as they would resist change anywaysSpending any time with the resistant population is a Waste.

Common Resistance Area Ignore the new process or the changeFail to understandDisagree with the validity of the benefitsCriticize new set of tools or applicationsDelay the implementation

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Phases of Six Sigma

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lean six sigma green belt training part 2

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