LSSG Green Belt Training

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LSSG Green Belt Training
Introduction to Lean Six Sigma
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Who is Responsible for LSS?
Defining Roles and Responsibilities
CHAMPION Senior manager responsible for overall success of project.
MASTER BLACK BELT Train/coach/mentor BBs, monitor progress.
BLACK BELT Full-time LSS employees, Lead, track project, mentor GBs.
GREEN BELT Work part-time on LSS in their work areas.
OTHER BELTS Team Members, Data Collectors, Subject Matter Experts (SMEs).
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Demings 14 PointsW. Edwards Deming (1900-1993)

• Create constancy of purpose for improvement
• Adopt a new philosophy
• Cease dependence on mass inspection
• Do not award business on price alone
• Work continually on the system of production and
  service
• Institute modern methods of training
• Institute modern methods of supervision of
  workers
• Drive out fear
• Break down barriers between departments
• Eliminate slogans, exhortations, targets for the
  work force
• Eliminate numerical quotas
• Remove barriers preventing pride of workmanship
• Institute a vigorous program of education and
  retraining
• Take action to accomplish the transformation

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Sigma (s) vs Sigma Level

• ? Standard Deviation
• a measure of variation around the average
• Sigma Level 1/2 the number of standard
  deviations (?) that will fit between the
  specification limits when the process is centered

Customer Specifications
ssssssss
8/2 4 ?
12/2 6 ?
Sigma level is also a measure of the number of
defects per opportunity produced by a process.
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Six Sigma Improvement Methods
Six Sigma accommodates both Improvement and
Reengineering
Define
Measure
DMADV
DMAIC
Analyze
Reengineering
Continuous Improvement
Design
Improve
Validate
Control
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Six Sigma Improvement - Role of Tollgates

• Ensure Sequence
• Obtain formal approval to move to the next DMAIC
  phase
• Prevent team from skipping steps
• Enable Communication
• Provide management with project updates at each
  level
• Allow Charter Updates
• Make modifications to project scope

Define
Measure
Analyze
Design
Improve
Verify
Control
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DMAIC Six Sigma - Define

• Objectives
• Identify Customers
• Complete Charter
• Understand Process

Tools Charter, VOC, VSM, CTQ SIPOC, Scorecards
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DMAIC Six Sigma - Measure

• Objectives
• Identify Inputs and Outputs
• Measure Process Capability
• Revise Charter

Tools Brainstorming, MSA, Walkthrough, CE, 5S,
KPOV, KPIVs, RTY, Benchmarking
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DMAIC Six Sigma - Analyze
Where are the key leverage points for driving
breakthrough performance?

• Objectives
• Determine Variation Sources
• Prioritize Key Outputs and Inputs
• Revise Project Benefits

Tools Fishbone Diagram, Pareto Chart, Process
Capability, Control Charts, Layout and Process
Flow Analysis FMEA, Statistical Analyses
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DMAIC Six Sigma - Improve
How do we get there?

• Objectives
• Develop Potential Solutions
• Develop Future State
• Evaluate and Mitigate Risk

Tools Kaizen Event, Contingency Planning, Pilot,
DOE, Optimization.
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DMAIC Six Sigma - Control
How Do We Keep the Gains?

• Objectives
• Implement Controls
• Standardize
• Evaluate Benefit

Tools Standardization, Training, Visual Aids,
Mistake Proofing, Documenting Benefits
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DMAIC Six Sigma - Design
How do we create and implement a new process that
will delight the customer and provide outstanding
business results?

• Objectives
• Design Product/Process
• Evaluate Product/Process Structure
• Evaluate Risk/Benefit

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DMAIC Six Sigma - Verify
How do we determine if the new process is
successful?

• Objectives
• Beta test
• Plan Implementation
• Implement Solution

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What is Lean?
Continuous Flow
Lean

• Customer Pull

LEAN - Like water running downstream - more speed
with less effort!
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The Lean Six Sigma Approach
Define Scope / Opportunity
Current State ? Future State ? Gap
Process cleanup 5S and other Lean Tools
Yes
No
Known Solution
6 Sigma Project
Lean Project
Yes
New Design?
DMADV
No
DMAIC