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