Lean 6 Solutions
Better Quality, Faster
Integrated Process Improvement
20 years of process improvement experience Certified Master Black Belt. Bachelor in Industrial Engineering, Masters in Project
Management Experience in Manufacturing and Service Industries. President of Lean 6 Solutions, Inc. – Lean Six Sigma
Consulting - www. Lean6solutions.com
Presenter Bio
Lucas [email protected]
Understand why continuous improvement is important. Describe Six Sigma, Lean, and Innovation. Using an integrated approach to improving your business. Using Lateral thinking to spur the innovation process. Developing a strategic implementation plan.
Objectives
Increasing competition worldwide. There is need to improve processes and develop new
ideas in many industries:- Education- Health care- Environmental protection- Government administration- Manufacturing
Do we need Continuous Improvement?
70-20-10 Rule“Spend 70 percent of your time on the core business, 20 percent on related projects, and 10 percent on unrelated new businesses” – Eric Schmidt: Google CEO
Integrated Process Improvement
Your integrated process improvement efforts need to include three sets of activities.
Related ProjectsUnrelated New Business
Improve Daily Work
Use of Lean concepts and tools. Includes the processes that people do every day in their job. Develop a culture where employees carry out small incremental improvements. Employees are expected to regularly identify improvements
in their workplace. Employees should be focused on key processes.
Improve Daily Work
Does not require formalized processes and data analysis. Problems can be readily detected by careful observation. Many solutions are “just do it” types.
Solution to the problem is apparent and just needs to be implemented.
Examples:- Make sure all job aids are available to workers- Share best practices- Organized workspace, databases, reference materials, etc
WasteNecessary
Value Added
Lean places work into one of three categories.
The customer only cares about the value added work.
The majority of all work is usually in the waste category.
Lean focuses on eliminating work that is in the “Waste” category.
Lean and Waste
Enables you to distinguish between normal and abnormal conditions.
Creates the foundation for continuous improvement. Allows visual communication. Involves the organization’s employees.
5S Concepts
Creating and maintaining an organized, safe, and visual workplace which:
Sort – Straighten – Shine – Standardize - Sustain
Standardized Work
Agreed upon work procedures that establish the best methods. Each step in the process is performed repeatedly in the same manner. Changes are only made when data indicates that a new method is better.
.
Structured Process Improvement
Use Six Sigma to address issues that are more complex. Focus on improving processes. Train individuals to use data based analysis for improvement.
Solution to the problem is not known
Use of structured techniques and data analysis is required. Examples: - Improve on-time delivery of a product- Reduce errors in a process.
DefineControl
Measure
Analyze
Improve
DMAIC
Improvement methodology that is focused on reducing variation.
Make decisions based on data and analysis.
Based on the DMAIC model and is used in every Six Sigma project.
Six Sigma and DMAIC
Example – Data Analysis
Day 1 Day 3Day 2
The run chart indicates that the majority of the abandoned calls are between 9 am – 11 am.
The next step is to analyze the reasons for abandoned call from 9-11.
Correlation Example
There is a moderate positive correlation between finish time and cyclist weight .
Fin
ish
Tim
e
Cyclist Weight
Innovation Projects
Use Design for Six Sigma and lateral thinking to develop new products and processes.
Understand the market, customer needs, and company core skills to make changes. Developing solutions that are different or new. Examples: - Launch a new product line- Market to a new customer segment- Redesign the sales process
Design For Six Sigma
Used when a new process, product, or service is needed or when existing ones require significant change.
Requires substantial work in understanding the voice of the customer - why can’t the process, product, or service meet customer requirements.
Is useful for collecting needs data, analyzing the data, and developing requirements.
Does not have good tools for developing new ideas.
Lateral Thinking
Term coined by Edward de Bono in Lateral Thinking. Systematic techniques used for changing concepts and
perceptions and generating new ones. Exploring multiple possibilities and approaches instead a
single approach. Sometimes defies logical thinking or the “data driven”
approach.
“You can not dig a hole in a different place by digging the same hole deeper.
1 2 3
Let’s make a deal Winner gets to pick a door•2 doors have gag prizes•1 door has a nice prizeAfter the door is selected, the MC will reveal one gag prize. You then have the option to switch doors or keep original choice.
Thinking Outside the Box
New ways to use as is? Other uses if modified?
What else is like this? What other ideas does this suggest? What could I copy?
New twist? Change colors, motion, odor, taste, form, and shape? Other changes?
What to add? More time? Greater frequency? Stronger? Higher? Larger? Thicker? Heavier? Extra value? Duplicate? Multiply?
What to subtract? Smaller? Miniature? Lower? Shorter? Lighter? Understate? Less frequent?
Who else instead? What else instead? Other material? Other process? Other approach? Other time?
Interchange components? Other pattern? Other layout? Other sequence?
Change place? Change schedule? Earlier? Later?
Innovator’s Checklist
Improve Daily Work - Hotel Example
Problem Improve Daily Work
Room cleaning too slow Share best practices
Customer complaints about drinks.
Change brand of drink
Miscommunication between shifts
10 minute communication meetings
Structured Projects - Hotel Example
Problem Structured projects
Room changeover from guest to guest is slow
Increase capacity of staff during peak checkout times
Check-in time is too slow Reduce time that is not value added in the process.
Breakfast invoice charged to wrong room
Change process so attendant asks for customer ID.
Innovation Projects - Hotel Example
Problem Innovation projects
Room changeover from guest to guest is slow
Reduced prices to guests for late check in.
Check-in time is too slow Self check in kiosks (like airports)
Breakfast invoice charged to wrong room
Finger print scanners for checkout.
Improvement Method
Regardless of the improvement method the following steps are required:
1) Selection of a process for improvement.
2) Identification of process problems that need attention.
3) Implementation and monitoring of improvement activities.
Select core processes that need improvement. Conduct monthly or bi-monthly brainstorming meetings
with personnel involved in the process. Meetings should be ½ day to 1 day in length. Collect all ideas regardless of the complexity or scope. Categorize ideas as:
- Improve Daily Work
- Structured Projects
- Innovation Projects
Brainstorming Meetings
50% of employees are involved in program
Train key individuals on Six Sigma tools and concepts.
Train key individuals on Innovation .
Realize financial targets>.25% of revenue.
Full-time improvement position added.
75% of employees are involved in program.
Fulltime positions are recognized as a desired development assignment.
Improvement projects started with business partners.
Realize financial targets = 1.00% of revenue
100% of employees are involved in program.
Strategic alignment business partner innovation efforts
Realize financial targets> 1.00% of revenue
Year 4Soar with EaglesYear 1
Start the engine
Year 3Gain AltitudeYear 2
Take Off
25% of employees are involved in program.
Start documenting core processes
Train individuals on Lean Tools and Concepts
Realize financial targets> 0.10% of revenue
Improvement Shaping Plan
QUESTIONS ??