Transcript LSSG Black Belt Training

LSSG Green Belt
Training
Introduction to Lean Six Sigma
Intro to LSS
1
Who is Responsible for LSS?
Defining Roles and Responsibilities
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).
Intro to LSS
2
Deming’s 14 Points
W. Edwards Deming (1900-1993)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Create constancy of purpose for improvement
Adopt a new philosophy
Cease dependence on mass inspection
Do not award business on price alone
Work continually on the system of production and service
Institute modern methods of training
Institute modern methods of supervision of workers
Drive out fear
Break down barriers between departments
Eliminate slogans, exhortations, targets for the work force
Eliminate numerical quotas
Remove barriers preventing pride of workmanship
Institute a vigorous program of education and retraining
Take action to accomplish the transformation
Intro to LSS
3
Sigma (s) vs Sigma Level
s = Standard Deviation

a measure of variation around the average
Sigma Level = 1/2 the number of standard deviations
(s) that will fit
between the specification limits when the process is centered
Customer
Specifications
ssssssss
= 8/2 = 4 s
ssssss ssssss
= 12/2 = 6 s
Sigma level is also a measure of the number of defects per opportunity
produced by a process.
Intro to LSS
4
Six Sigma Improvement Methods
Six Sigma accommodates both
Improvement and Reengineering
Define
Measure
Analyze
Improve
Design
Control
Validate
Intro to LSS
5
Six Sigma Improvement Role of Tollgates

Ensure Sequence



Measure
Analyze
Enable Communication


Define
Obtain formal approval to move
to the next DMAIC phase
Prevent team from skipping
steps
Provide management with
project updates at each level
Allow Charter Updates

Make modifications to project
scope
Intro to LSS
Improve
Design
Control
Verify
6
DMAIC Six Sigma - Define
Objectives
 Identify Customers
 Complete Charter
 Understand Process
Control
Improve
Analyze
Tools
Charter, VOC, VSM, CTQ
SIPOC, Scorecards
Define
Measure
Intro to LSS
7
DMAIC Six Sigma - Measure
Objectives
 Identify Inputs and Outputs
 Measure Process Capability
 Revise Charter
Control
Improve
Analyze
Tools
Brainstorming, MSA, Walkthrough,
C&E, 5S, KPOV, KPIVs, RTY,
Benchmarking
Define
Measure
Intro to LSS
8
DMAIC Six Sigma - Analyze
Where are the key leverage points for
driving breakthrough performance?
Objectives
 Determine Variation Sources
 Prioritize Key Outputs and Inputs
 Revise Project Benefits
Control
Improve
Analyze
Define
Measure
Tools
Fishbone Diagram, Pareto Chart,
Process Capability, Control Charts,
Layout and Process Flow Analysis
FMEA, Statistical Analyses
Intro to LSS
9
DMAIC Six Sigma - Improve
How do we get there?
Objectives
 Develop Potential Solutions
 Develop Future State
 Evaluate and Mitigate Risk
Control
Improve
Analyze
Tools
Kaizen Event,
Contingency Planning,
Pilot, DOE, Optimization.
Define
Measure
Intro to LSS
10
DMAIC Six Sigma - Control
How Do We Keep the Gains?
Objectives
 Implement Controls
 Standardize
 Evaluate Benefit
Control
Improve
Analyze
Define
Measure
Tools
Standardization, Training,
Visual Aids, Mistake Proofing,
Documenting Benefits
Intro to LSS
11
DMAIC Six Sigma - Design
How do we create and implement a new process that will delight
the customer and provide outstanding business results?
Objectives
Verify/
Validate
Design



Analyze
Design Product/Process
Evaluate Product/Process Structure
Evaluate Risk/Benefit
Define
Measure
Intro to LSS
12
DMAIC Six Sigma - Verify
How do we determine if the new process is successful?
Verify/
Validate
Objectives
 Beta test
 Plan Implementation
 Implement Solution
Design
Analyze
Define
Measure
Intro to LSS
13
What is Lean?
JIT Delivery
Elimination of NonValue Add Activity
Visual Management
Continuous Flow
Genuine Focus on the
Customer
Customer Pull
Culture for
Lean
Increase
Offering/Decrease
Changeover
Kaizen Events
Lean Tools, Methods
and Measures
LEAN - Like water running downstream - more speed with less effort!
Intro to LSS
14
The Lean Six Sigma Approach
Define Scope / Opportunity
Current State 
Future State

Gap
Process cleanup
5S and other Lean Tools
Yes
No
Known Solution
6 Sigma
Project
Lean Project
Yes
DMADV
New Design?
No
DMAIC
Intro to LSS
15