lean six sigma for all sectors - starchapter · pull, work cell, load balancing and level...
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Charanjit Singh (CJ) BawaPMP, Black Belt & Change AgentLean Coach, QCDMS Consultants
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Lean Six Sigma For All Sectors
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IMPROVE QUALITY
INCREASE SAFETY
LOWER COSTS
REDUCE DELIVERY TIME
ENHANCE MORALE
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We support organizations to:
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1. SHOW RESPECT2. GO SEE & FIND
WASTE3. ASK WHY & ENGAGE
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Core Values of Lean Six Sigma
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DDefects
OOverproduction
WWaiting
NNon-utilized talent
TTransportation
IInventory
MMotion
EExtra processing
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Lean= Removal of 9 Wastes
Recently discovered 9th waste = Prioritization
Lean removes waste, redundancies, inefficiencies, roadblocks and bottlenecks out of your organization.
Example: A manufacturing plant reduced their product Lead time from 10 days to 30 minutes.
Six Sigma- Reduce Variation
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Six Sigma reduces variation and improves your process
capability.
Example: A medicine manufacturing company reduced variation in their
mixing process.
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Mix Ratio percentage
Histogram Before
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Mix Ratio percenage
Histogram After
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Training
Group Facilitation
Consulting
Coaching
Our Lean Six Sigma Services
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Training and coaching process
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Trainees work on company’s actual
processes & identify
opportunities
Handson practical Games to
engage trainees
Focused questions & group
discussions
Lego tactile exercises
Coaching your team on
company’s processes
Training throughmedia and
actual case studies
QCD
MS
Water Leak
Water Leak
Case Study 3 Your Problem
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1. Organization’s
Culture &
Leadership Skills
4. Process Improvement
3. Problem Solving
2. Daily Management
towards a Purpose
Lean Philosophy, Principles &
Tools
WHITE BELT YELLOW BELT GREEN BELT (5 Days)
COMPETENT
Process Improvements
PROFICIENT
Process Improvements + Problem Solving
EXPERT
Can Embed culture of Lean Six Sigma and coach teams on Process Improvement &
Problem Solving
½ to 1 Day 2 Days +3 Days for Yellow
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Lean Six Sigma Certifications
BENEFITS- Improved quality & efficiency, on-time delivery, reduced safety incidents,
enhanced customer and employee morale = INCREASED PROFITABILITY $$
PROCESS IMPROVEMENTS
PROCESS IMPROVEMENTS
COMPLEX PROBLEM SOLVERS +
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Lean Yellow Belt (2Days)
COMPLEX PROBLEM SOLVERS
PROCESS IMPROVEMENTS +
Goal- Trainees will be able to improve their processes with the help of Lean Event
methodology and Six Sigma- DMAIC or Toyota- A3 Problem Solving thinking.
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Goals and Objective
Goal- Train staff to improve their processes with the help of Lean Event methodology and Six Sigma- DMAIC or Toyota- A3 Problem Solving thinking.Duration- 2 DaysCourse Pre-work – Trainees bring a small to medium size Process and Problem to the trainingTraining overview-• Lego Simulation (Round 1 and 2)• Introduction to Lean • Lean Management and Philosophies• Basic Statistics (Measure of Central Tendency)• Lean or Kaizen Event Methodology applied on Trainee’s Processes 7 QC Tools Six Sigma (Define – Measure- Analyze- Improve- Control) or Toyota & Honda (A3
Thinking) Problem Solving applied on Trainees problems
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Yellow Belt overview
Yellow Belt 1st day
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1st half day (before lunch) 2nd half day (after lunch)
Introduction to Lean
• History of Lean
• KPIs and 3 P’s of Lean (Purpose, People and Process)
• Show Respect, Go See and Ask Why
• Simulation (Round 1)
About Lean
• Lean 8 Waste, VA, NVA, Inefficiencies, Muda, Mura Muri
• Two Lean 8 Waste Exercises.
1. Trainees watch video and finds 8 Waste and
2.Trainees list all the 8 waste that they see in work)
• Lean philosophy and principles
5 Principles of Lean
House of Toyota
JUST IN TIME- Lead Time, Takt Time, Cycle Time, FIFO, 1 Piece Flow,
Push Vs. Pull, Work Cell, Load Balancing and Level Scheduling
STANDARDIZATION- Visual Management, 5 S, Point of Use and Skills
Development
JIDOKA- Quality Control Vs. Quality Assurance Poka Yoke and Andon
• Process Mapping Tools - SIPOC, Swim Lane, Process Walk Template and
Value Stream Map
• Applying Lean Philosophies and Principles in Simulation (Round 2)
• Measures of Central Tendency – Min, Max, Range, Mean, Median, Mode and
80th Percentile
• Toyota’s 14 Management Principles
Lean or Kaizen Event Methodology
Background and basics of process improvement
Share one case study from Service sector
Trainees bring their processes and apply lessons
learned into their own processes
Teach Lean Event methodology (6 step process)-
1. Choose a process- Team Charter (Voice of
Customer, Objective, Milestones, Team formation and
more)
2. Data collection, Process Walks and creating Current
State Value Stream Map,
3. Lean or Kaizen events (1 to 3 days)
Review Charter and Objectives or KPIs,
Agree on Current State Map,
Finding Inefficiencies,
Clustering Inefficiencies & finding top priority
Themes,
Root Cause Analysis,
Creating Action Plan,
Work Breakdown Structure,
Drawing Future State Map,
Target Setting,
Report Out to Senior Leadership
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2nd half day (before lunch) 2nd half day (after lunch)
Lean or Kaizen Event Methodology
4. Complete Action Items
5. Regular update meetings and monitor action
plan and KPIs
6. Check benefits, Control and Close out Project
• Share Lean Event report out template
7 QC Tools
Histogram, Scatter Diagram, Fishbone, Bar
Chart / Run Chart / Control , Pareto Analysis,
Check Sheet, Process Mapping
A3 Problem Solving methodology
Provide Introduction to Root Cause Analysis
Simple Root Cause Analysis by using simple tools like “5Why” and “5W 2H”
Share Honda’s , 11 steps “A3 Problem Solving” methodology for complex
problems
Share case study from Service sector
Trainees bring their problem and apply Problem solving in their own setting
Compare Honda’s A3 Problem solving with Six Sigma D-M-A-I-C approach
and Ford 8D
DEFINE – Team Charter that includes Problem Statement
(Specification or Target Vs. Actual), Team Formation, Project Charter
and Background of the problem
MEASURE - Understanding the Current state, Data Collection and
Temporary Solution
ANALYZE – Root Cause Analysis, Fishbone Diagram, Finding
probable root causes and Testing or Trials to find the right root cause
IMPROVE- Solutions, SMART Action Plan with WBS
CONTROL – Monitor, Check Effectiveness , Statistical Process
Control, Sustainment and Standardization
Share Problem Solving report out template
Yellow Belt 2nd day
Our trainees came from:
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MANUFACTURING SERVICE
PUBLIC SERVICE HEALTHCARE
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Pictures from our events
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Open Training Coaching on Lean Event Public speaking
Organizational Training Coaching at client side Group FacilitationPublic Service
Public Service
Team Building- Service
OACETT chapter dinner PMI Open Lean Six Sigma
Yellow Belt Training
1 piece flow - Manufacturing
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About CJ (Lean Six Sigma Coach)
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• Passionate, Results-Driven Professional and Public Speaker
• PMP, Black Belt, Change Agent and Mechanical Engineer• 24 Years of Lean six sigma , Change Management &
project management experience • Trained 6300 professionals, coached more than 160
Improvement project teams , from 50 organizations, across all sectors
• Coached 50 leadership teams• Industries served – Automotive (OEM- Daewoo &
Honda), Auto Parts Manufacturing, Service, Healthcare & Public service
• He can be contacted at [email protected] or call him at 416 571 8770
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