Lean six sigma

LeanSixSigma1ConfidentialLean6SigmaCoreIntroductiontoLean6Sigma●Introductions●ValueofSpeed●ImpactofVariation●5S●DMAIC●KaizenusingDMAIC●IncorporatingDMAICintoaKaizen(GoFast)EventIntroModule1.1ConfidentialSafetySafety:–Fireexitsandwheretocongregate–Tripandotherhazards–EH&SResourceName:PhoneNumbers:–FacilityContactPhone#:–LocalContactPhone#:–EmergencyPhone#:Logistics:–Restroomsandbreaks/lunchaccommodations–Wewillbegineachdayinthisroomat8amConfidentialCourseObjectives•Ensureaclearunderstandingofhowprocessspeedandvariationimpactprocessefficiency(cost,speed,andflexibility)•Gainahands-onunderstandingoftheLean6Sigmaimprovementmethodology(DMAIC)•Developapracticalunderstandingofwasteeliminationandvariationreductiontools,techniques,andtheoryConfidentialDMAICImprovementProcessRoadMap•ReviewProjectCharter•ValidateProblemStatementandGoals•ValidateVoiceoftheCustomerandVoiceoftheBusiness•ValidateFinancialBenefits•ValidateHigh-LevelValueStreamMapandScope•CreateCommunicationPlan•SelectandLaunchTeam•DevelopProjectSchedule•CompleteDefineGate•IdentifyPotentialRootCauses•ReduceListofPotentialRootCauses•ConfirmRootCausetoOutputRelationship•EstimateImpactofRootCausesonKeyOutputs•PrioritizeRootCauses•CompleteAnalyzeGate•DevelopPotentialSolutions•Evaluate,Select,andOptimizeBestSolutions•Develop‘To-Be’ValueStreamMap(s)•DevelopandImplementPilotSolution•ConfirmAttainmentofProjectGoals•DevelopFullScaleImplementationPlan•CompleteImproveGate•ImplementMistakeProofing•DevelopSOP’s,TrainingPlanandProcessControls•ImplementSolutionandOngoingProcessMeasurements•IdentifyProjectReplicationOpportunities•CompleteControlGate•TransitionProjecttoProcessOwner•ProjectCharter•VoiceoftheCustomerandKanoAnalysis•SIPOCMap•ProjectValuation/ROICAnalysisTools•RACIandQuadCharts•StakeholderAnalysis•CommunicationPlan•EffectiveMeetingTools•InquiryandAdvocacySkills•TimeLines,Milestones,andGanttCharting•ParetoAnalysis•BelbinAnalysis•ValueStreamMapping•ValueofSpeed(ProcessCycleEfficiency/Little’sLaw)•OperationalDefinitions•DataCollectionPlan•StatisticalSampling•MeasurementSystemAnalysis(MSA)•GageR&R•KappaStudies•ControlCharts•Histograms•NormalityTest•ProcessCapabilityAnalysis•ProcessConstraintIDandTaktTimeAnalysis•CauseandEffectAnalysis•FMEA•HypothesisTests/Conf.Intervals•SimpleandMultipleRegression•ANOVA•ComponentsofVariation•ConqueringProductandProcessComplexity•QueuingTheory•ReplenishmentPull/Kanban•StockingStrategy•ProcessFlowImprovement•ProcessBalancing•AnalyticalBatchSizing•TotalProductiveMaintenance•DesignofExperiments(DOE)•SolutionSelectionMatrix•PilotingandSimulation•Mistake-Proofing/ZeroDefects•StandardOperatingProcedures(SOP’s)•ProcessControlPlans•VisualProcessControlTools•StatisticalProcessControls(SPC)•SolutionReplication•ProjectTransitionModel•TeamFeedbackSession•ValueStreamMapforDeeperUnderstandingandFocus•IdentifyKeyInput,ProcessandOutputMetrics•DevelopOperationalDefinitions•DevelopDataCollectionPlan•ValidateMeasurementSystem•CollectBaselineData•DetermineProcessCapability•CompleteMeasureGateToolsActivitiesKaizen,5S,NVAAnalysis,GenericPullSystems,FourStepRapidSetupMethodIdentifyandImplementQuickImprovementsImproveAnalyzeControlMeasureDefineConfidentialHowToDriveContinuousImprovementImproveCost,SpeedandFlexibilitySetupReductionOperationTimeImprovementDefectPreventionProcessFlowImprovementTotalProductiveMaintenanceGageR&RContinuousImprovementToolkitVisualControlsVisualManagementandFeedbackPullSystemsOperationalExecutionKaizenImplementationDashboardsValueStreamMapsControlChartsDataCollectionPlanningConfidentialLean6SigmaTraining:Subjects•Lean6SigmaConcepts•Kaizen•5S•VisualControls•DMAIC•LeanProcess•Little’sLaw•ProjectCharter•ProjectScope●StakeholderAnalysis●ValueStreamMapping●RootCauseAnalysis●OperationalDefinitions●Sampling●DataCollectionPlanning●ScatterPlots●DefectPrevention●Dashboards●ControlPlanConfidentialConduct:GroundRules•CellPhones,Pagers,andBlackBerrydevicesturnedofforonvibrate.(Ifyouhavetoansweranemergencycall,pleasedosooutsidetheroom.)•MeetingEffectivenessToolsinplace(Goals/Objectives,Agenda,MeetingRoles,ParkingLot,BenefitsandConcerns)•Oneconversationatatime•Wewillstart/endontime•Frequentbreakstostayfresh•Two-waycommunicationrequired(AdultLearningEnvironment)ConfidentialExpectationsInstructors’expectationsarethatyouwill:–Haveadefinedproject(problem)–Activelyparticipateinclass(includingteamactivities)–Cometoclassprepared–CompleteProjectCharter/DefinePhase–Startadatacollectionplan–HaveFun!!!ConfidentialExpectations(Cont.)Whatweexpectyoutogainfromthistraining:•HowLean6Sigmafitswiththecorporatestrategyandhowexecutionisessentialtoourbusiness•SolidunderstandingoftheintegrationandpowerofLean6Sigma•LearnandapplytheprocessimprovementmethodologyofDMAIC•UtilizeDMAICina“Go-Fast”methodologytoreducewasteandvariationTopicswewillNOTcoverinthistraining:•Thoroughcoverageof6Sigma(statistical)toolsandtechniques•PullSystemcalculations•ThoroughcoverageofLean(process)toolsandtechniquesConfidentialRoles:InstructorIntroductions•YearsExperience•FormerEmployers•AreasofEx