Lean Six Sigma Implementation
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The document outlines the implementation of Lean Six Sigma, combining Lean tools and Six Sigma methodologies to enhance process efficiency by eliminating waste and defects. It discusses key principles, such as the laws of Lean Six Sigma, which highlight the importance of addressing customer quality issues, maintaining flexibility, and focusing on the most impactful activities within processes. The document further describes a structured deployment plan, including initiation, resource selection, project implementation, and measures for success.
Lean Six Sigma Implementation
- 1. Lean Six Sigma Implementation Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 2. Agenda • Combining Lean and Six Sigma • The Laws of Lean Six Sigma • Deploying Lean Six Sigma Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 3. Combining Lean and Six Sigma • The Lean Six Sigma Approach combines – The DMAIC Methodology (from Six Sigma) – Quality Tools (used in both Six Sigma and TPS) – Lean Tools (from TPS) Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 4. Lean and Six Sigma Tools System Lean / Toyota Six Sigma Production System Philosophy •Elimination of •Reduction of waste defects/variation Improvement •PDCA •DMAIC Process/Cycle Tools VSM, 5S, Process Mapping, Standardized Work, SIPOC, Hypothesis Leveling, SMED, Testing, DOE, TPM, One Piece Control Charts, etc. Flow, Kanban, etc. Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 5. The Laws of Lean Six Sigma Lean Six Sigma, George, 2002 • Lean means speed; it applies to all processes. • Slow processes are expensive processes. • The Lean metric is process cycle efficiency (Value-added Time/Total Lead Time) • Batch sizes must be calculated using flow variables • 95% of the lead times in most processes is wait time. • To improve speed, you need to identify and eliminate the biggest time traps using the Laws of Six Sigma Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 6. The Laws of Lean Six Sigma Lean Six Sigma, George, 2002 • Laws of Six Sigma – The Law of the Market: Customer CTQ (critical-to- quality) issues must be addressed first. – The Law of Flexibility: Process Velocity is directly proportional to flexibility. – The Law of Focus: 80% of the delay in any process is caused by 20% of the activities – The Law of Velocity: The average velocity of flow through any process is inversely proportional to both the number of “things” in the process and the average variation in supply and demand. Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 7. Execution of Lean Six Sigma 1. Initiation – Top Management becomes engaged in supporting the initiative. 2. Resource and Project Selection • Linked to Customer CTQ • Focus on creating value (high NPV projects) 3. Implementation / Sustainability / Evolution Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 8. Deployment Plan • Process • Organization • Measures • Rewards • Tools Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 9. Deployment Plan • Process Org Results VSM Projects Goals ($) Select Identify Quality Products / Opportun- DMAIC Productivity Value ities Kaizen Inventory Streams (Projects) Lead-Time Sales Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 10. Deployment Plan • Organization Executive Leadership Resources Accountability Project Champions Resources Accountability Master Process Black Belt Black Belt Owners Team Members Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 11. Deployment Plan: Organization MBB Black Belts Green Belts Yellow Belts Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 12. Deployment Plan • Measures – Leading Indicators • # of champions identified • # of BB/GB identified and trained • Size and value of project queue – Financial Improvements linked to each initiative • Quality • Productivity • Inventory • Lead-Time • Sales Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved
- 13. Deployment Plan • Rewards – Bonuses tied to project performance (savings generated) for team leaders/participants. – Recognition – visible support from executives Copyright © 2005-2008 EMS Consulting Group Inc. All Rights Reserved