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Lean Six Sigma Overview
WELCOME, THE WEBINAR WILL COMMENCE IN A FEW MINUTES
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2Welcome
Thank you for participating, Welcome to this Webinar
Today’s Webinar Subject:
Lean Six Sigma Overview
Speaker:
Joe BarckettMaster Six Sigma Black Belt
For Audio: Switch on your computer speakers
3
Joe Barckett – Senior Consultant & Master Black Belt
Significant experience (over 28 years) in the development and implementation of quality management systems including 6 Sigma &Lean technologies into top companies within the manufacturing and service industries.Held a variety of positions ranging from Quality Statistician, Quality Engineer, Quality Assurance Manager, TQM Coach and Director of Quality. As Director of Quality for a $3 billion high-tech Fortune 500 consumer product company, led the organization to ISO 9001 registration and a state Pioneer Award based on the Malcolm BaldrigeNational Quality Award criteria. BS in Mathematics from the University of Massachusetts at Dartmouth, and MA in Mathematics from Arizona State University. Served as a Senior Examiner for the 1995 Arizona Governors Quality awards, and in 1996-1997 for the Massachusetts Council for Quality award.
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Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up
Webinar Agenda
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Some SAI Global Six Sigma Results: Manufacturing
72k 90% Automotive Manufacturer
120k 10% Paper Manufacturer
51k 50% Aerospace Oil Cooler
Manufacturer
100k 70% Telecommunications Wire
Manufacturer
1.4M 50% Telecommunications Wire
Manufacturer
10k 87% Stators Manufacturer -Air
Conditioners
250k 92% High Tech Manufacturer
Monetary SavingsDefect ReductionIndustry
Manufacturing
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Some SAI Global Six Sigma Results: Service
420k 95% Telecommunications Service
400k 95% Telecommunications Service
159k - -Telecommunications Service
166k 38% Service HVAC Calls - Property Management
182k 75% Back Order Reduction
500k 61% Out of Stock Product Expedite Cost Reduction
170k 86% Service Catalogue Error Reduction
Monetary SavingsDefect ReductionIndustry
Transactional
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Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up
Webinar Agenda
8Quality Gurus
Dr. Joe Juran
Philip Crosby
Dr. K. Ishikawa
Dr. G. Taguchi
Dr. W. Edwards Deming
9Similarities
Customer focused
Senior management commitment
Culture of continuous improvement
Employee involvement
Process approach
Process improvement methodology: PDCA
Data driven
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Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up
Webinar Agenda
11History of Six Sigma
If Japan …PBS/IBM/NBC
6/24/80
ASQ Certified
Six Sigma Black Belt
Early Adopters and Consultancies
Black Belt
structure first used
Supplier Base
Motorola Wins
Baldridge
1980 1985 1990 1995 2000 2005
Mass Adopters: including
Transactional and Public Sectors
Dr. Deming Bill Smith Jack Welch
12What is Six Sigma?
1. A summary statistic
2. A process performance metric
3. Philosophy of continual improvement
131. A Summary Statistic
Standard deviation
− s, sample standard deviation
− σ, population standard deviation
Standard deviation is a measure of dispersion that takes into account each of the data points and their distance from the mean
1n
)XX(s
2i
n
1i
−
−=∑=
A deviation!0
12 2
34
01234
1 2 3 4 5 6
Data Set: 0, 1, 2, 2, 3, 4
X
142. Process Performance Metric
Counts
− sigma levels
− dpmo
− ppm or yields
Measure
− sigma levels or z scores
− Process capability
− Cp and Cpk
152. Sigma Levels
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Sigma Yield DPMO
1 σ2 σ3 σ4 σ5 σ6 σ
30.85%69.15%93.32%99.38%99.977%
99.99966%
691,500308,50066,8006,2002303.4
2. Defects and Sigma Levels
A defect is any instance or event in which the product or process fails to meet a customer requirement.
173. Philosophy of Continual Improvement
Built into the day-to-day workings of the company
Everything they do is focused on improvement
183. Ways to Improve a Process
1. Shift the mean
2. Reduce variability
3. Stabilize over time
4. Capable over time
UCL
LCL
CL
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Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up
Webinar Agenda
206 Sigma Foundation
1.Process
Improvement
DMAIC
2.Process
Design/Redesign
DFSS
3.Process
Management
211. DMAIC: Process Improvement
Referred to as continual improvement or incremental improvement:"recurring activity to increase the ability to fulfil requirements".
Seeks to fix a problem while leaving the basic structure in place.
The emphasis is on finding and targeting solutions to address the “vital few” factors (the Xs) that cause the problem or pain (the Y).
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Illustrate Baseline and
Capability
Characterize Data and Sampling
Validate Measurement
System
Develop Stratification
Plan
Map Process with Data MMeasure
CIdentify
Replication Opportunities
Validate Improvements
Develop Sustainability
Plan
Validate Savings
Transition to Process Owners
Control
Validate Root Causes
Root Cause Analysis
Stratification Analysis
Value Add Analysis AAnalyze
Map New Process I
Develop Potential Solutions
Pilot SolutionsImprove Implement Solutions
Estimate Financial Benefits
Map High Level Process
Identify Stakeholders
State Problem
Develop ScheduleIdentify RiskSelect Team
and Launch
Validate Project
Selection
D
Define Validate Scope
Obtain Voice of the Customer
DMAIC Roadmap
232. DFSS: Process Design/Redesign
DFSS: Design For Six Sigma
Often incremental change does not result in breakthrough improvements
Processes may not be long term capable
Process design/redesign complements process improvement.
The objective is not to “fix” but to “replace” a process or part of a process.
24Other Acronyms for DFSS
DMADV
− Define, Measure, Analyze, Design, Verify
− Similar to DMAIC approach
IDOV
− Identify, Design, Optimize, Verify
− Focused on final stage engineering optimization
DMEDI
− Define, Measure, Explore, Develop and Implement
− Emphasizes being creative
25DMADV Overview
The design’s effectiveness is verified for its use/operation.Verify
The good/service/process is designed. The design concept is validated using predictive models, simulation, prototypes, pilotruns, etc.
Design
Analyze the options available for meeting the goals. Determine the performance of similar best-in-class designs.
Analyze
Critical to Quality characteristics are measured to ensure requirements are translated into project goals.
Measure
The goals for the design are definedDefine
263. Process Management
“Process approach”:
− The application of a system of processes within an organization
− the identification and interactions of these processes, and their management
Provides ongoing control over the linkage between the individual processes within the system of processes
Discussed in ISO 9000
273. Process Management (cont.)
Processes are documentedCustomer requirements are clearly definedMeasures of outputs, process activities, and inputs are thorough and meaningfulMeasures and process knowledge are used to assess performance in “real time” and take action to address problems
28Why is 6 Sigma Different?
1. Customer focused 2. Bottom line/results focused/partnership with Finance3. A process not just a set of tools4. Forces project alignment5. Data driven/Statistically supported/validated decisions6. Balances intuition with statistical thinking7. Includes the whole value chain (SIPOC)8. Creates true quality metrics (How well)9. Equally at home in different organizational environments10. Something in it for employees: certification/a portable skill set11. Built-in infrastructure12. Leverages a universal methodology/applied learning13. Gives permission to improve a process
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Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up
Webinar Agenda
30“Belt” Roles
8. Advanced statistician
9. Instructor
10. Organizational psychologist
11. Integrity and ethics officer
5. Mentor
6. Statistician
7. Program manager
1. Data analyst
2. Facilitator
3. Project manager
4. Change agent
Role
½ to 2 years1 – 2 yearsMaster Black
Belt(Masters)
5 months to 1 year
4 weeksBlack Belt(Sophomore – Senior)
5 to 9 months1 week
(2 week)Green Belt
(Freshman)
Project Duration
TrainingBelt
31Critical Roles and Responsibilities
Select projects
Scope projects and write charters
Provide resources and remove roadblocks
Mentor gate reviews
− Understand DMAIC
− Know what questions to ask
− Recognize tools used
Close projects
Ensure validation of improvements and savings
Ensure sustainability
Replicate opportunities
Celebrate and certify
Responsibilities
Sponsor / Champion
Role
32Critical Roles and Responsibilities
Leverage special expertise (knowledge, skill, or method)
Serve as core or extended team member
Usually a controller or analyst
Help estimate potential savings
Validate project savings
Own process
Serve on project teams
− At least one core team member must own the process
− An effort should be made to include all process owners
Sustainability of improvements
Responsibilities
Subject Matter
Experts
Financial Analyst
Process Owner
Role
33Sample 6 Sigma Implementation Timeline
MonthActivity 1 2 3 4 5 6 7 8 9 10 11 12
1 Day
3 - 4 Days
4 Weeks
1 Week Standard
Phase 1 Planning
Champion Training
Project Selection
Black Belt Selection
Black Belt Training Wave 1
Green Belt Selection
Green Belt Training Wave 1
Project Completion Wave 1
Phase 2 Planning
Executive Overview
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Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up
Webinar Agenda
35Wrap Up
Increase Revenue
Provide Best Customer Experience
Improve Profitability
Increase Productivity
Create Culture of Performance
Six Sigma Lean
can help with all of these!
36Contact Us
Website:
www.saiglobal.com/training/assurance
Phone:
1-800-374-3818
E-mail for Joe:
37About us SAI Global
SAI Global, is an applied information services company, helps you
manage risk, achieve compliance and drive improvement
Applied information services
Publications
Add value publish and distributestandards, regulatory, and technical information
Develop andlicense Information
Sources of information
Training
Enhance throughtraining & consultingservices
Assurethroughindependent assessment
AssuranceCompliance
Create & Deliverawareness communication and monitoring solutions
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Our MottoSemper “Gumby”
“Always Flexible”
Our Vision Statement:
“To become the premier provider of enhanced and integrated business management systems that go beyond compliance and focus
our clients on sustainable business performance.”
About us SAI Global
39First Class Registration & Training
Registration Services - Merged with QMI, to become QMI-SAI Global to become one of the largest global registrars
Superior Training and Improvement Solutions - across the United States, Canada and now Mexico
− Understanding, Implementing and Auditing Training − ISO Standards, Management Systems and Process Improvement Training across a wide
range of industries and topics
2010 Public Training Calendar - www.saiglobal.com/training/assurance
In-house Training – Courses can be delivered at your premises/preferred location
Commitment to customer and corporate continual improvement
Industry Experts, Trainers and Auditors with over 40+ combined experience
Over 200,000+ people trained worldwide
Successful projects with hundreds of companies • Focus is achieving ongoing Business Improvement through the use of international standards
as a starting point
− Medical Device − OHSAS 18001− Automotive− Six Sigma and Lean + More
− Food Safety− ISO 9001 − ISO 14001− AS 9100/AS 9110
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www.saiglobal.com/training/assurance
41Sampling of Course Offerings
• Full curriculum of Six Sigma Lean offerings• Deploying A Lean Enterprise Initiative• Continual Business Improvement• Process Mapping• Innovation / Creative Problem Solving• Understanding and Measuring Customer Satisfaction• Balanced Scorecard • Effective Corrective and Preventive Action • Risk Management• Design Control for the Medical Device Industry• Skills for Success for the Management Representative• Process Based Auditing for Business Improvement• Benchmarking and Measuring Business Performance• Integrated Business Solutions / Business Excellence
42Thank you
Call us - 1-800-374-3818
Email us: [email protected]
Website: www.saiglobal.com/training
Have a Great Day