Lean Six Sigma Flashcards and Potential Application to Improvement Exercises in Academic & Corporate Education

Lean Six Sigma Project Tool Selection Exercise

November 6, 2017

Agenda

q Issue q Development of Toolkits Card Deckq Introduction to LSS Project Tool Plan Exercise

§ Paper Puppet Simulation§ Project Selection § Tool Selection§ Debrief

q Initial Survey Resultsq Conclusion

Toolkits

What kinds of tools do I want

to carry?

How would you organize them?

Lean Six Sigma Toolkits

Which one? When?

Problem

Ø We cover more than 100 tools and concepts during the semester.

Ø Trainees understand each tool when we cover the specific tool.

Ø Trainees could not effectively organize all tools at the end of training period.

Ø As a result, don’t know what/when to use…

Which tool would you choose?

Fishbone for Problem or Opportunity?

Opportunity

Problem

Development of LSS Toolkits Card Deck

Total 64 Tool Cards Deck• Lean(L): 13 tools• Six Sigma (S): 13 tools• Basic Quality (Q):14 tools• Basic Statistics (T): 21 tools

Development Process of Card Deck

Initial Design

MVP

Test

Pilot Production

Final Production

• Problem Identification• Initial Design through Tool Presentation

• Produce MVP (Minimum Viable Product)• Image Design and Contents Writing

• Class Simulation • Survey

• Small batch of pilot production • Review and Revision

• Final Production• Implementation

Purpose of Exercise

Ø Participants will better understand which tools to use for each stage of a LSS project.

Ø Participants will better understand the differences among various tools.

Ø Participants will better understand the overall flow of planning a LSS project.

The Flow of Full-Exercise

Process Simulation

Project Selection

Individual Tool 

Selection

Team Discussion

LSS Toolkit Card 

Review

Individual Tool 

Selection

Team Discussion Debrief

Start

End

Let’s Try!

백문이불여일견!百聞而不如一見!

One Picture is worth a Thousand Words!

“En Bild sagt mehr als tausend Worte”

Paper Puppet: Process Analysis Simulation

(Originally published by Prof. Janelle Heineke, 1997 and modified by Prof. Yoo Taek Lee, 2017)

Lean Six Sigma Problem-solving Flowchart

(Source: Tina Huesing, Motorola, October, 2008, modified by Kook Hyun Moon)

Project Selection by Team (or Individually)

XY-Prioritization Matrix

Cost

Ease of im

plementation

Resource

Availability

… Total

Project Weighted Average  30 20 20 … 100

Improve the cutting task 5 5 5 … 500

Redesign the process 5 5 3 … 460

… …

Step 1St

ep 2

Step 3

Step

 4

Project Selection by Team (or Individually)

Easy of Implementation

Impa

ct

High

Low

EasyDifficult

Top PicksConsider

Last Likely Potential Investment

What method will you use?

PDCA

Plan

Do

Check

ActSix Sigma 

Project Initial Proposal

Ø Project Description: Briefly describe your project

Ø Main Approach:

Ø Lean Six Sigma Project: D-M-A-I-C

Ø Lean Six Sigma Kaizen: P-D-C-A

The Flow of Full-Exercise • Paper Puppet Simulation.• Discussion on Paper Puppet Simulation.

• Distribute LSS Toolkits Card Deck.• Ask trainees to organize the card in categories for review.

• Distribute Form 3 Ind_A.• Ask trainees to select tools for each question based on the card review.

• Distribute Form 4 Team_A.• Ask team to discuss and select an agreed tool for each question.

• Distribute Form 2 Team_B.• Ask Team to discuss and select agreed tool for each agreed question.

• Discuss why trainees changed their tool selection if there was any.• Discuss what kind of tool each team selected and why.

Process Simulation

Project Selection

Individual Tool Selection

Team Discussion

LSS Toolkits Card Review

Individual Tool Selection

Team Discussion

Debrief

• Distribute Form 1 Ind_B.• Ask Trainees to develop three questions and select tools for each question.

• Form a team• Ask each team to select the potential project and method

Form 1: Ind_B (Individual Before)

Step  Main Questions for each step Tools1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

Ø Depending on the characteristic of identified problem, users are asked to develop three most critical questions for each stage and select most effective tool for each question.

Form 2: Team_B (Team Before)

Step  Main Questions for each step Tools1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

Ø Work with your team to select the three most critical questions for each stage and most effective tool for each question.

Review of LSS Toolkits Card Deck

Total 64 Tool Cards Deck• Lean(L): 13 tools• Six Sigma (S): 13 tools• Basic Quality (Q):14 tools• Basic Statistics (T): 21 tools

Form 3: Ind_A (Individual After)

Step  Main Questions for each step Tools1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

Ø Depending on the characteristic of identified problem, select most effective tool for each question by using LSS Toolkits Card Deck. If you do not find the tool from the existing cards, you can create your own card by using the empty cards.

Form 4:Team_A (Team After)

Step  Main Questions for each step Tools1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

1)2)3)

Ø Work with your team to select the main questions for each stage and most effective tool for each question by using LSS Toolkits Card Deck.

Exercise Time Plan ( 3 hour session including break)Time 

Commitment Step of Exercise

5 min. Introduction10 min. Paper Puppet Exercise10 min.  Discussion 5 min.  Situational Map Introduction (or review)

20 min. Team Project and Method Selection

20 min.  Fill out LSS Tool Plan Form 1 (Form 1 Ind_B)

20 min.  Fill out LSS Tool Plan Form 2 (Form 2 Team_B)

10 min.  Card Distribution and Review 15 min. Break15 min.  Fill out LSS Tool Plan Form 3 (From 3 Ind_A)

25 min.  Fill out LSS Tool Plan Form 4 (Form 4 Team_A)

25 min Discussion and Debrief

The Flow of Simple Version Exercise

Process Simulation

Project Selection

Individual Tool 

Selection

LSS Toolkit Card 

Review

Team Discussion Debrief

Start

End

The Flow of Simple Version Exercise

• Paper Puppet Simulation.• Discussion on Paper Puppet Simulation.

• Distribute LSS Toolkits Card Deck.• Ask trainees to organize the card in categories for review.

• Distribute Form 4 Team_A.• Ask team to discuss and select an agreed tool for each question.

• Discuss why trainees changed their tools selection if there was any.• Discuss what kind of tool each team selected and why.

Process Simulation

Project Selection

Individual Tool Selection

LSS Toolkits Card Review

Team Discussion

Debrief

• Distribute Form 1 Ind_B.• Ask Trainees to develop three questions and select tools for each question.

• Form a team• Ask each team to select the potential project and method

Exercise Time Plan ( 1.5 hour session)

Time Commitment Step of Exercise

10 min. Introduction & Paper Puppet Exercise10 min.  Discussion 5 min.  Situational Map Introduction (or review)

15 min. Team Project and Method Selection (Focused on the Bottleneck problem)

15 min.  Fill out LSS Tool Plan Form 1 (Form 1 Ind_B)

10 min.  Card Distribution and Review

15 min.  Fill out LSS Tool Plan Form 4 (Form 4 Team_A)

10 min Discussion and Debrief

Let’s Try the Mini Exercise!

Test of Effectiveness

Courses Number Class Description

Class Size Remarks

OM840 P1 Winter Break Intensive class 54

Part-time/ 2nd year MBA students/other college

OM840 F1 Evening MBA class 31 Part-time /2nd year MBA

students/other college

OM840 M1 Daytime MBA class 51 1st year MBA students

OM465 A1 Undergraduate class 33 Senior students

Survey Questions

Q1: Did the cards help you better understand various tools?

Q2: Did the cards help in selecting a proper tools for each step of the selected approach?

Q3: How would you rate the quality of picture design of flashcard?

Q4: How would you rate the quality of text description of flashcard?

Q5: Overall, did it help?

Effectiveness of LSS Toolkits Card Deck

Effectiveness of LSS Cards Design

Q3

Q3

Q3

Q4

Q4

Q4

Overall Effectiveness

Conclusion

Ø Support trainees in better understanding various tools

Ø Help trainees to better organize various tools

Ø Assist trainees to better manage the improvement project by providing tool selection plan

Ø Provide a potential reference material that can be used in the field

Thank you!

Any Questions or

Feedback?