Transcript Six Sigma - Learning With Larry

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What is Six Sigma?
What:
Data driven method of identifying and resolving variations in processes.
How:
Driven by close understanding of customer needs, disciplined use of facts, data and
statistical analysis.
Attention to managing improving and reinventing business processes.
Proactive vs Reactive
A way of thinking – Culture Change
Works for both Manufacturing and Service processes
Welch
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Outcomes and Questions
Outcomes
Initial Questions
•Cost reduction
• What does each process need
• Productivity improvement
• What does each process provide
• Market- share growth
• How is the process evaluated
• Customer retentions
• Who is responsible for the process
• Cycle-time reduction
• Defect reduction
Proactive
• Culture change
• How long will my customers be
satisfied with my current performance.
• Product/service development
• There are always competitors
• What can we achieve that we had not
thought of.
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DMAIC
D - Define
M - Measure
Approaches
1. Project Team
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Full time black belts
Part time team members
Duration 1- 4 months
A - Analyze
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- Improve
C - Control
2. Kaizen
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Lead by black belt
All members full time
Define function done before
Duration: 1week or less
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Define
Goal: The team and its sponsor reach agreement on the scope,
goals, financial targets and performance targets for project.
Steps:
1. Review draft project charter from sponsor.
2. Validate problem exists & important and goals are reasonable
3. Validate Financial benefits ( current vs target results)
4. Create and Validate process map and scope
5. Create Communication Plan ( who and when to keep informed)
6. Develop Project Plan ( schedule, budget, milestones)
If necessary do Define step as a mini - Kaizen
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Measure
Goal: understand the current state of the process and collect reliable data on
process speed, quality and costs that you will use to expose the underlying
causes of the problems.
Steps:
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Create/validate a value stream map to confirm current process flow.
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A basic process map with defect rate, processing time, complexity, queue
time, setup time
Identify the outputs, inputs and process variables relevant to your project
Create a data collection plan including operational definitions for all measures
Create a data analysis plan ( statistical methods to be used)
Use accurate and calibrated measurement instruments
Collect data to establish baselines
Update value stream maps with new data
Make quick hit improvements
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Analyze
Goal:
To identify the causes affecting the key input and output variables tied to project
goals
Steps:
1. Identify Value-Added vs non Value-Added steps (Conduct Value Analysis)
2. Compare your current process metrics to benchmarks (Process Cycle Efficiency)
3. Analyze the process flow for bottlenecks, constraints, rework points for impact
4. Analyze data collected in Measure step.
5. Generate theories to explain potential causes
6. Narrow the search
7. Collect additional data to verify root cause
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Improve
Goal:
To learn from pilots of the selected solution(s) and execute full scale implementation
Steps:
1. Develop potential solutions based on the root causes found in the Analyze step.
2. Develop Criteria, evaluate, select, and optimize best solutions.
3. Develop “To Be” value stream map. ( what metrics you want to see)
4. Develop and implement pilot solution.
5. Confirm attainment of project goals
6. Develop and execute full-scale implementation plan
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Control
Goal:
To complete project work and hand off improved process to process Owner, with
procedures for maintaining the gains
Steps:
1. Develop supporting methods and documentation
2. Launch Implementation
3. Lock in Performance gains
4. Monitor implementation
5. Develop Process Control Plans and hand-off control to process owner
6. Audit the results
7. Finalize Project
8. Validate performance and financial results
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Videos
Funny 6 Sigma
Lean Mfg
Cartoon
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