Lean Six SigmaLean Six Sigma

Knowledge of Lean 6Knowledge of Lean 6σσ Tools can Tools can help you in your daily work.help you in your daily work.

What is LEAN?What is LEAN?

a practice that considers the a practice that considers the expenditure of resources for any expenditure of resources for any goal other than the creation of goal other than the creation of value for the end customer to be value for the end customer to be wasteful, and thus a target for wasteful, and thus a target for eliminationelimination

MORE VALUE, LESS WORKMORE VALUE, LESS WORK

What is Six Sigma?What is Six Sigma?

A business management A business management strategy that seeks to identify strategy that seeks to identify and remove the causes of and remove the causes of defects and errors in defects and errors in manufacturing and business manufacturing and business processesprocesses

A six sigma process only has A six sigma process only has 3.4 defects per million 3.4 defects per million opportunities opportunities 99.9997% efficiency99.9997% efficiency

Six Sigma – Removing Six Sigma – Removing defectsdefects

Striving for PERFECTION!!Striving for PERFECTION!! Improve processesImprove processes Reduce variationReduce variation

Use data to identify causes of Use data to identify causes of defects or variationdefects or variation

Why is variation a problem?Why is variation a problem?

Six Sigma Method - DMAICSix Sigma Method - DMAIC

DefineDefine SMART goalsSMART goals

MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl

Six Sigma ToolsSix Sigma Tools

Are you a DATA HEAD???Are you a DATA HEAD??? Pareto ChartPareto Chart Ishikawa DiagramIshikawa Diagram Control ChartsControl Charts 5 Why’s5 Why’s

5 Whys?5 Whys?

Used to determine the root Used to determine the root cause of a defect cause of a defect

Ask why the defect is occurring?Ask why the defect is occurring? Then ask WHY again?Then ask WHY again? And again And again And againAnd again And again until you get to the root And again until you get to the root

cause of the defect.cause of the defect.

Questions about 6Questions about 6σσ??

Lean – removing WASTE Lean – removing WASTE (MUDA)(MUDA)

Seven Types of WasteSeven Types of Waste OverproductionOverproduction WaitingWaiting Transportation/MotionTransportation/Motion Over processingOver processing Inventory Inventory Rework/DefectsRework/Defects VariationVariation

Lean ToolsLean Tools

5S5S Just in TimeJust in Time Poka-yokePoka-yoke Value Stream MappingValue Stream Mapping

5S Philosophy5S Philosophy

Organizing and managing the Organizing and managing the workspace and flow to improve workspace and flow to improve efficiency.efficiency. SortSort StraightenStraighten ShineShine StandardizeStandardize SustainSustain

Just in TimeJust in Time

Production of a product so that Production of a product so that Is just in time for delivery to Is just in time for delivery to customer. customer.

Less inventoryLess inventory Different signals call for more or Different signals call for more or

less productionless production

Poka Yoke – Mistake ProofingPoka Yoke – Mistake Proofing

How can you keep the error from How can you keep the error from occurring?occurring? Elimination – redesign process to Elimination – redesign process to

eliminate the chance of the erroreliminate the chance of the error Facilitation – provide guidance to Facilitation – provide guidance to

minimize the chance of the errorminimize the chance of the error Mitigation – lessen the effect of the error Mitigation – lessen the effect of the error

on the consumeron the consumer Flagging – ensure the removal of all Flagging – ensure the removal of all

defective pieces before it gets to the defective pieces before it gets to the consumerconsumer

Value Stream MappingValue Stream Mapping

Used to analyze the steps in a Used to analyze the steps in a process that get a product to a process that get a product to a consumerconsumer Map the current stateMap the current state Determine how waste can be Determine how waste can be

eliminatedeliminated Draw a future stateDraw a future state Make it happenMake it happen

Value Stream MappingValue Stream Mapping

To get the process right you To get the process right you need to understand the need to understand the sequence of activities – what sequence of activities – what steps add value?steps add value?

Questions about LEAN?Questions about LEAN?

Final ThoughtsFinal Thoughts

It does not matter what you call it – It does not matter what you call it – Lean Six Sigma, Total Productive Lean Six Sigma, Total Productive Manufacturing (TPM), Total Quality Manufacturing (TPM), Total Quality Management (TQM), Operational Management (TQM), Operational Excellence Excellence It is all about being efficient and doing It is all about being efficient and doing

things for a reason, not just because things for a reason, not just because that is the way it has always been that is the way it has always been

Remove variationRemove variation All steps in any process should add All steps in any process should add

value to the customer and they should value to the customer and they should be willing to pay for it.be willing to pay for it.

Let’s Get Started!!!Let’s Get Started!!!PURCHASE TO PAYMENTPURCHASE TO PAYMENT

We are mapping out this process to create a clear picture of the steps involved to order and pay for an item purchased on campus.  Identify what steps in the process are breaking down and where we can become more efficient.

SIPOC DiagramSIPOC Diagram

Suppliers – Providers of inputSuppliers – Providers of input Input – Items that are needed to Input – Items that are needed to

complete the processcomplete the process Process – High level 5-7 stepsProcess – High level 5-7 steps Output – Results of the processOutput – Results of the process Customers – Receivers of the Customers – Receivers of the

outputoutput