Lean Six Sigma

Quality means
doing it right
when no one is
looking.
Henry Ford

Getting Started
Welcome to the Six Sigma workshop.
The last couple of decades companies
have embraced Six Sigma to generate
more profit and greater savings. So
what is Six Sigma?
Six Sigma is a data-driven approach
for eliminating defects and waste in
any business process.
Notting Hill College School of Business

Lean Six Sigma

Workshop Objectives

Develop a 360 degree view of Six Sigma and how it can be implemented in any
organization.
Identify the fundamentals of lean manufacturing, lean enterprise and lean principles.
Describe the key dimensions of quality product features and freedom from
deficiencies
Develop attributes and value according to the Kano Model
Understand how products and services that have the right features and are free from
deficiencies can promote customer satisfaction and attract and retain new customers.
Describe what is required to regulate a process
Give examples of how poor quality affects operating expenses in the areas of
appraisal/inspection costs, internal failure costs and external failure costs
Using basic techniques such as DMAIC and how to identify Six Sigma Projects
Use specific criteria to evaluate a project
Discover root causes of a problem
Design and install new controls to hold the gains and to prevent the problem from
returning.

Notting Hill College School of Business

Lean Six Sigma

Six Sigma is the

most important
training thing we
have ever had. Its
better than going
to Harvard
Business School.
Jack Welch, GE

Understanding Lean
Lean and Six Sigma are like buzzwords we hear in business all of
the time. Before we get started,
lets make sure we all understand
just what we mean by Lean and
Six Sigma.

Notting Hill College School of Business

Lean Six Sigma

About Six Sigma

Six Sigma is a structured, data-driven process
of solving critical issues from a business
perspective that we havent been able to solve
with current methodology.
Six Sigma is the single most effective problemsolving methodology for improving business
and organizational performance.
Notting Hill College School of Business

Lean Six Sigma

About Lean
Lean means continuously improving
towards the ideal and achieving the shortest
possible cycle time through the tireless
reduction of waste.

Notting Hill College School of Business

Lean Six Sigma

History behind Lean

The phrase lean manufacturing was coined
in the 1980s.
Most of the basic goals of lean manufacturing
are common sense, and some fundamental
thoughts have been traced back to the
writings of Benjamin Franklin.

Notting Hill College School of Business

Lean Six Sigma

Toyota Production Systems

TPS revolves around 5 simple steps:
Define Value of your product
Identify Value Stream of your product
Study the Flow your product
Make only what the customer orders
Strive for Perfection

Notting Hill College School of Business

Lean Six Sigma

The Toyota Precepts

The 5 methods defined by Toyota contain some
basic principles:
CHALLENGE
KAIZEN
GENCHI GENBUTSU (Go and see)
RESPECT
TEAMWORK
Notting Hill College School of Business

Lean Six Sigma

Do you value
practices, or do
you practice
values?
Unknown

Likers Toyota Way

In this module we will look closer
at Toyotas philosophies that have
become a spiritual pinnacle of
modern manufacturing.
The Toyota Way is a book about
the 14 principles that drive Toyotas
culture.
Notting Hill College School of Business

Lean Six Sigma

A Roadmap for implementation

A Six Sigma initiative occurs in five major stages:
Initialize Six Sigma by establishing goals and
installing infrastructure
Deploy the initiative by assigning, training and
equipping the staff
Implement projects and improve performance
Expand the scope of the initiative to include
additional organizational units
Sustain the initiative, through re-alignment, retraining and evolution.
Notting Hill College School of Business

Lean Six Sigma

13

15

17

Value Stream Analysis

Start with Process Map.
For each step, identify type of action:
VA
NVA, but necessary given current limitations
(Type I Waste)
NVA that can be immediately eliminated (Type
II Waste).

Go beyond the walls of your organization:

Consider supply of materials and end customer.

Sort
Straighten
Shine
Standardize
Sustain

.
.
.
.
.

Sort
.
.
.

Sustain

Straighten

Standardize

1.
2.
3.
4.

5.

Shine

Sort:
Eliminate whatever is not
needed
Straighten:
Organize whatever remains.
Shine:
Clean the work area.
Standardize:
Schedule regular cleaning and
maintenance
Standardize process
Sustain:
Make 5 S a way of life

TPM is a Lean tool to optimize the effectiveness

of manufacturing equipment and tooling
1. Starts with 5S / Visual Factory
2. Builds a comprehensive Downtime Database by
cause, frequency, and duration
3. Predicts and prevents downtime by PM system
4. Expands role of Operator as first point of
early warning and prevention
5. Develops Professional Maintenance skills

Takt, Cycle and Lead Time

Takt Time must be distinguished from Cycle Time and

from Lead Time.
Cycle Time is the actual time to accomplish a task
within a process. All tasks should be synchronized to
takt time, so that the waste of overproduction is
eliminated.
Lead time is the time that is required from receipt
of order until shipment to the customer

Push vs. Pull Scheduling

Push scheduling
Traditional Approach
Move the job on when finished
Problems- creates excessive inventory
Pull scheduling
Coordinated production.
Driven by demand (pulled through system)
Extensive use of visual triggers
(production/withdrawal kanbans)

Poke-yoke is A method that uses sensor or other devices for catching

errors that may pass by operators or assemblers due to human error.
Poka-yoke effects two key elements of ZDQ:
Identifying the defect immediately ( Point of Origin Inspection)
Quick Feedback for Corrective Action

Poka-yoke detects an error, gives a warning, and can shut down the
process.

3.5 inch diskettes cannot be inserted unless diskette

is oriented correctly. This is as far as a disk can be inserted
upside-down. The beveled corner of the diskette along with
the fact that the diskette is not square, prohibit incorrect
orientation.