Intro to LSS 1

LSSG Green Belt Training

Introduction to Lean Six Sigma

Intro to LSS 2

Who is Responsible for LSS?

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).

Defining Roles and Responsibilities

Intro to LSS 3

Deming’s 14 PointsW. Edwards Deming (1900-1993)

1. Create constancy of purpose for improvement2. Adopt a new philosophy3. Cease dependence on mass inspection4. Do not award business on price alone5. Work continually on the system of production and service6. Institute modern methods of training7. Institute modern methods of supervision of workers8. Drive out fear9. Break down barriers between departments10. Eliminate slogans, exhortations, targets for the work force11. Eliminate numerical quotas12. Remove barriers preventing pride of workmanship13. Institute a vigorous program of education and retraining14. Take action to accomplish the transformation

Intro to LSS 4

Sigma () 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

= 8/2 = 4

= 12/2 = 6

Sigma level is also a measure of the number of defects per opportunity produced by a process.

Intro to LSS 5

Six Sigma Improvement Methods

Define

Measure

Analyze

Design

Validate

Improve

Control

Six Sigma accommodates bothImprovement and Reengineering

Intro to LSS 6

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

Verify

Improve

Control

Intro to LSS 7

DMAIC Six Sigma - Define

ObjectivesObjectives Identify Customers Complete Charter Understand Process

Measure

Control

Analyze

Improve

DefineToolsCharter, VOC, VSM, CTQSIPOC, Scorecards

Intro to LSS 8

DMAIC Six Sigma - Measure

ObjectivesObjectives Identify Inputs and Outputs Measure Process Capability Revise Charter

Measure

Control

Analyze

Improve

DefineToolsBrainstorming, MSA, Walkthrough,C&E, 5S, KPOV, KPIVs, RTY,Benchmarking

Intro to LSS 9

DMAIC Six Sigma - Analyze

ObjectivesObjectives Determine Variation Sources Prioritize Key Outputs and Inputs Revise Project Benefits

Measure

Control

Analyze

Improve

Define

Where are the key leverage points for driving breakthrough performance?

ToolsFishbone Diagram, Pareto Chart,Process Capability, Control Charts, Layout and Process Flow AnalysisFMEA, Statistical Analyses

Intro to LSS 10

DMAIC Six Sigma - Improve

ObjectivesObjectives Develop Potential Solutions Develop Future State Evaluate and Mitigate Risk

Measure

Control

Analyze

Improve

Define

How do we get there?

ToolsKaizen Event,Contingency Planning,Pilot, DOE, Optimization.

Intro to LSS 11

DMAIC Six Sigma - Control

ObjectivesObjectives Implement Controls Standardize Evaluate Benefit

Measure

Control

Analyze

Improve

Define

ToolsStandardization, Training,Visual Aids, Mistake Proofing, Documenting Benefits

How Do We Keep the Gains?

Intro to LSS 12

DMAIC Six Sigma - Design

ObjectivesObjectives Design Product/Process Evaluate Product/Process Structure Evaluate Risk/Benefit

Measure

Verify/Validate

Analyze

Design

Define

How do we create and implement a new process that will delight the customer and provide outstanding business results?

Intro to LSS 13

DMAIC Six Sigma - Verify

ObjectivesObjectives Beta test Plan Implementation Implement Solution

Measure

Verify/Validate

Analyze

Design

Define

How do we determine if the new process is successful?

Intro to LSS 14

What is Lean?Elimination of Non-Value Add Activity

Customer Pull

Genuine Focus on the Customer

Culture for Lean

Lean Tools, Methods and Measures

Kaizen Events

JIT Delivery

Increase Offering/Decrease

Changeover

Visual Management

LEAN - Like water running downstream - more speed with less effort!

Continuous Flow

Intro to LSS 15

The Lean Six Sigma Approach

Define Scope / Opportunity

Current State Future State Gap

Process cleanup5S and other Lean Tools

Known Solution

Lean Project6 Sigma Project

New Design?

DMADV

DMAIC

Yes

No

Yes No