Development, Validation, Implementation and Enhancement of a Voluntary Protection Programs Center of

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Development, Validation, Implementation and
Enhancement of a Voluntary Protection Programs
Center of Excellence (VPP CX) Capability for
Department of Defense (DoD)

• Lean / Six Sigma and VPP

Department of Defense Voluntary Protection
Programs Center of Excellence Operated by
DoD Lead AgentOffice of the Assistant
Secretary of the Army (Installations and
Environment)
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Objectives

• After this training you will be able to
• Describe Six Sigma and Lean approaches
• Identify the five steps of the Six Sigma Process
• Describe Lean 5S
• Understand how Lean / Six Sigma compliment VPP
• Discuss the role of Leadership in Lean / Six
  Sigma and VPP.

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Lean and Six Sigma

• Six Sigma is a system of data driven statistical
  process control
• Lean focuses on process flow and eliminating
  waste
• Lean and Six Sigma compliment each other in a
  culture of continuous improvement.

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Six Sigma
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Six Sigma

• Six Sigma is a
• Goal where organizations should
• operate at less than 3.4 defects per
• million opportunities
• Philosophy dedicated to reducing
• defects and variations in processes,
• products and services
• Metric where communication is more
• effective by using the same
• standards throughout the organization.

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Six Sigma Process

• There are five steps to the Six Sigma process
• Define Phase
• Measure Phase
• Analyze Phase
• Improve Phase
• Control Phase.

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Six Sigma Define Phase

• The Define Phase objective is to understand the
  requirement, goal(s) and current process.
• Define the safety or health
• requirements and goal(s)
• Define how the current process works.

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Six Sigma Measure Phase

• The Measure Phase objective is to assess current
  safety performance
• Define incident, near misses,
• severity, potential hazard, etc.
• Develop data collection system,
• gather incident information and
• measure baseline performance
• Identify areas with most incidents or
• highest risk (i.e. the critical few).

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Six Sigma Analyze Phase

• The Analyze Phase objective is to determine which
  safety problems to solve in what order
• Evaluate and prioritize work activities
  associated with incidents
• Determine root causes and possible
  countermeasures
• Identify and prioritize gaps in the current
  process.

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Six Sigma Improve Phase

• The Improve Phase objective is to identify and
  implement optimal change solutions
• Evaluate and prioritize
• corrective / preventive measures
• Eliminate incidents through
• process re-design and error proofing
• Deploy effective corrective/
• preventive measures.

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Six Sigma Control Phase

• The Control Phase objective is to sustain,
  enhance and improve process performance
• Continuously evaluate and improve, using the
  Plan, Do, Check, Act (PDCA) Cycle.

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Six Sigma VPP
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Six Sigma Mapped to Stages Elements of VPP
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Lean
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Lean

• Process Management Philosophy
• Eliminate Wastes
• Smooth and Efficient Work Flow
• The Original Seven Wastes
• Evolving Thoughts on Waste
• Safety
• Unsafe work areas create lost work hours and
  costs.
• Skills
• "It is only by capitalizing on employees'
  creativity that organizations can eliminate the
  other seven wastes and continuously improve their
  performance."

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Lean 5S Process

• Lean 5S originated in Japan in the 1960s as a
  technique of good housekeeping and workplace
  organization.
• The 5 Ss are
• SORT Go through everything keep only what is
  needed
• STORE A place for everything in a way that
  promotes good work flow
• SHINE Clean everything
• STANDARDIZE Make standards visually obvious
  everyone does things the same way
• SUSTAIN Keep it that way.

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Good Floor Examples of 5S
Improves production while avoiding safety and
health incidents
APU Tool Box (One section for each APU type)
Reduces trip hazards Less fatigue Fewer
ergonomic incidents
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Good Floor Examples of 5S
Organization assists the self-inspection process.
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Good Office Examples of 5S
Standard location for pen, stamp, etc.
Bins indicate time a fax order was received
Ergonomic benefits Improve morale
Faxes for personnel go here
Schedule of order entry personnel
Work space for current order processing only.
Bins indicating delays in order processing -
visually escalating problem orders
White board captures problems with delayed order
processing
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Lean / Six Sigma and VPP
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Lean / Six Sigma and VPP

• Keys to Lean / Six Sigma Success
• Management Commitment
• Time and Resources
• Clear Performance Goals
• Visible Leadership.
• Employee involvement
• Training and Tools
• Improvements Driven by Data
• Systematic Processes
• Plan-Do-Check-Act
• Continuous Improvement
• Support from qualified professionals.

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Lean and Six Sigma Teach Tools and Techniques
That Can Support and Reinforce VPP
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Leadership Role
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Leadership Role

• Expect Safety to be part of every Lean / Six
  Sigma event
• Support both - time and resources
• Use skills acquired for Lean / Six Sigma for VPP
  initiatives
• Provide cross training opportunities for Lean /
  Six Sigma and Safety and Health professionals
• Personally participate in Lean / Six
  Sigma and VPP events.
• Lead by Example

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Summary

• In this session you learned about
• Lean and Six Sigma approaches
• The five steps of the Six Sigma process
• Lean 5S
• How Lean / Six Sigma compliments VPP
• The role of Leadership in Lean / Six Sigma and
  VPP.

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Questions?