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ALHodlinS

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    Todays Roadmap

    1. Inside Output: Making Quality Statements

    2. The Management System

    3. Begin With the End In Mind

    4. The Standardization Tool

    5. The Improvement Engine

    6. Putting It All Together

    7. The Dual Function of Work

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    33

    Who is DST Output?

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    44

    DST Output

    High volume experience and capabilities

    Comprehensive servicesInnovation and recognitionSize and stability

    A top outsourcer of print and electronic customer communications

    HARTFORD, CT

    EL DORADO HILLS, CA

    KANSAS CITY, MO

    TORONTO & OTTAWACANADA

    BRISTOLUNITED KINGDOM

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    DST Output: High volume

    experience and capabilities2.6 billion customer communications annually

    Largest third-party First-Class mailer in U.S.

    Worlds largest inkjet systems printer

    Large scale facilities in key regions:East, West, Central, Canada and UK

    Nearly 3,000 North American associates

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    The Company We Keep

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    DST Output Business

    Output Options

    Fold, Collate, Insert

    Envelopes P r i n t

    PresentmentPayment

    Distribution E l e c t r o n i c

    Address Express

    Move Update

    Mail Tracking, Processing P o s t a l File & Data Management

    Design and Development

    Campaign Management

    Online Reporting

    Monitoring

    Disaster Recovery

    Distributed Printing

    A Common Platform

    Market expertise in Communications, Financial Services, Insurance,Healthcare, Utilities and more

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    Customer Platform

    Optimizingclient outputrequirements Output Media Router

    Data Receipt &

    Management

    Data Prep Campaign

    Manager

    Content

    Composition

    Document

    Formatting

    Requirements Gathering

    ManufacturingSystems

    Optimizing printand electronic

    costs

    InFact, Mfg Preparation,Execution & Control

    eSolutions, Web Presentment,Payment & Distribution

    Quality ValidationJob Release

    TrackingReporting

    eSolutionsCD/DVD

    Presentment

    CD / DVDOutput Delivery

    Marketing,Ops, CSR

    Consumers CSR,Intermediaries

    DSTCustomer

    Portal

    Mail Delivery, Website,Secure e-mail, Portals

    Client Data Files

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    Operations Process

    Fan FoldStack Cart

    InsertInserter

    Pkgfeeder

    collatecutter foldmergesheetfeeder

    Statement Assembly

    Automated Container Line

    USPS

    InsertInserter Outstacker to

    Mail Conveyor

    Flats andSpecial Handling

    Manufacturing System Control

    Customer Data

    FileReceipt

    & Mgmt

    Data Prep Ancillary Products

    Formatting

    AFPMetacode

    Tracking and Reporting

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    LEADERSHIP

    STRATEGY

    CUSTOMER &MARKET FOCUS

    WORKFORCEFOCUS

    PROCESSMANAGEMENT

    RESULTS

    MEASUREMENT, ANALYSIS & KNOWLEDGE MGT.

    ResultsTriadLeadershipTriad

    Bicycle System

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    The Baldrige Award enjoys very broad, positive recognition amongleaders in each of the Baldrige Award-eligible sectors. ... More than 70percent of leaders surveyed among Fortune 1000 companies said they

    are likely to use the Criteria for Performance Excellence.

    Booz Allen Hamilton

    Results: Better employee relations

    Higher productivity

    Greater customer loyalty Increased market share

    Improved profitability

    The Baldrige Framework

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    What is Business Excellence? Business Excellence is a strategy that makes

    quality an integral part of the way business is

    designed Goes beyond the quality of products and services,

    and takes on a broader meaning of maximizing theeffectiveness of the business in meeting orexceeding customer value expectations and usingcontinuous improvement to drive business results

    It is the total quality of how the business operatesas a system.

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    B EGIN WITH THE END IN MIND

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    Key Excellence Indicators:Leadership

    Communication of and role model for the

    organizations values Legal and ethical behavior

    Focus on learning at all levels of the organization

    Good citizenship

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    Traditional Thinking that

    Drives Complexity Blanket solutionsManagers believethey know all

    Focused on thefinal result, noton the means

    Result-oriented

    Knowers FragmentedThinking

    Fragmented actionsLack of organization

    wide strategy

    Defensive Command& ControlFailure is notallowedEmployees feel

    the need to justify

    their actions Metrics and status reportsused as the primarymanagement tool 22

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    Lean Thinking Drives Continuous

    ImprovementLets identify theproblem and solve it togetherManagers are learnersand partners

    Focused on themeans to achievethe results

    Process and peopleare aligned toachieve organizational

    goalsEngagingCreate an environment

    where it is OK to fail and

    experimentation is

    encouraged Go See

    Mentor people todevelop problem solvers

    19

    SystemsThinking

    ProcessOriented

    Leader asa teacher

    Learner

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    2020

    Begin with the End in MindStrategy is the path for attaining the vision

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    Key Excellence Indicators: StrategicPlanning

    Balance of short- and long-term views

    Aggressive goal setting Strong work system alignment with strategy

    Systematic approach to addressing all sources ofrisk

    Failing to Plan is Planning to Fail

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    The Plan framework

    Vision: We are the premierprovider of statement and

    billing output solutions

    Mission: Make every customerreference-able

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    Our Strategic Goals Grow revenue and profitability

    Improve customer and alliancesatisfaction

    Achieve standardized infrastructureand tools across centers

    Continue operational excellence

    Institutionalize continuousimprovement

    Develop high-performance culture

    Institutionalize continuousimprovement

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    S trategic Planning Category

    Continueinstitutionalizingcontinuousimprovement

    NGT 1 ppmincidents .72

    G

    Jan 1.01 April 1.32 July - .32Feb 1.05 May .57

    Aug - .58Mar .37 June .52 Sept - .54

    Hodlin

    Restructure ELDP(Executive

    LeadershipDevelopmentProgram)

    Project PlanMilestones Q4 2009

    G

    Q2 finalize research for new content (6/09 on target)research phase on target

    Q3 researching more content options with budget proposal to MCQ4 build content structure; assessment on target/2010 ELDP in proposed status in budget due to largefocus on training from Quality Culture both nationallyand KC pilot program.

    Sutherland

    ()

    Project PlanMilestones

    Q1 2009(measures

    through 09)G

    Q1 - Complete curriculum build completeQ2 Rollout/Announcement to CS Department

    CS managers & above training , curriculum in completeQ3/Q4 - Quarterly feedback; Q3 reminders andmanager documents shared with user. Planningmeeting schedule .Hand off meeting for maintenance on target.

    Sutherland

    Lower Costs and improve efficienciesImprovecommingling

    profitability

    $X profit$Y InFactrevenue

    $Z legacyrevenue

    x Profity InFactz Legacy

    G

    Profit. .InFact Revenue.Legacy Revenue. Salls / Tapke /Mason /

    Sunset legacyapplications andcontinue toimplementstandardized

    processes acrossOperations

    Project PlanMilestones

    &Audit non -

    conformance toMPTQMinternal &

    external audits

    Met or Not G

    MPTQM internal audits meet requirements EastUSPS audit scheduled for July passed.MPTQM internal audits meet requirements WestUSPS audit scheduled for AugustMPTQM audits meet requirements Central USPSaudit scheduled for Nov.17 of the top 20 TA2000 clients have migrated,remaining 3 planned; 50 additional client applicationsidentified and prioritized. MPTQM internal auditsmeet requirements.

    Carnesecca /Hodlin

    Optimize real estate

    utilization Annualizedsavings $500K 124% YTD G

    Hill top cafe building has been closed and lease was

    terminated as of .YTD savings through end of Sept are approximately$620K.Associates have moved out of Crown Colony buildingin .

    Burns

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    Rolling Out Continuous

    Improvement Exceed customer expectations

    and drive results

    Dual Function of Work Daily Work andImprovement Work

    Strategy based BaldrigeCriteria for PerformanceExcellence

    Six Sigma & Lean driveprocess improvement

    ISO 9000 (MPTQM) to enablestandardization of processes

    CMMi and TMM used toidentify development

    improvement levels andopportunities

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    2727

    Performance Indicators

    Deliverables

    Key Result AreasFinancial Deliverables-First Time Quality-Organizational

    Effectiveness-Customer Satisfaction-Market Share

    Strategy

    VisionWhere is the organizationgoing?

    How do we get there?

    What do we need todo well to achievethe strategy?

    How do wemeasurehow wellwe aredoing?

    Strategy Deployment

    27

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    Key Excellence Indicators: Customer Focus

    In-depth market knowledge and forecasts

    Consideration of needs of current and potential

    customers

    Proactive customer contact

    Multiple mechanisms to identify customer requirements

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    Market Knowledge and Forecasts

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    Key Excellence Indicators: CustomerFocus

    Focus on enhancing customer relationships andloyalty

    Effective and prompt resolution of complaints

    High levels of customer satisfaction and repurchase

    Overall Satisfaction

    2 0 0 5 2 0 0 6 2 0 0 7 2 0 0 8 2 0 0 9

    Likelihood to Recommend

    2 0 0 5 2 0 0 6 2 0 0 7 2 0 0 8 2 0 0 9

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    3333

    Key Excellence Indicators:

    Measurement, Analysis, andKnowledge Management

    Use of fact-based decision making

    Collection of actionable data

    Use of multiple aligned and interlinking measures

    (internal and external) Wide deployment and accessibility of data and

    information

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    Key Excellence Indicators:

    Measurement, Analysis, &Knowledge Management

    Strong analysis capability Benchmarking of best-in-class processes and

    results

    Reliable, secure, and user-friendly systems

    Organizational knowledge captured and sharedinternally and with key partners and suppliers

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    Selecting Metrics The Formula

    UnderstandEvaluateControlPredict

    Attribute Of The EntityThe

    InOrder

    To

    Goal(s)To

    To Evaluate The

    % Of KnownDefects CorrectedDuring Development

    InOrder

    To

    Correct AllDefectsBefore

    Shipping

    Example

    Running an organization is like

    driving a car. You need thecorrect metrics to ensure youare on track towards meeting thegoal.

    36

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    Metrics Car Analogy

    Odometer

    Voltage Regulator

    Speedometer Coolant TempTachometer

    Fuel Gauge

    Oil Pressure

    Customer SatisfactionCustomer FeedbackCustomer Inquiries

    Releases to ScheduleRequirements

    Associate SatisfactionSelf-assessment

    EfficiencyStandard Op. Procedures

    Bugs per release/developer Tools

    Development ReworkRepeat BugsErrorsFaultsFailures

    Performance to BudgetResourcesTraining

    Performance to Strategic GoalsMeasurements over timeCMMSDLCDST AuditSAS 70Self-assessment

    Systems UptimeNetwork metricsSystem Response

    Which are In-Process Measures?Which are Lagging Indicators?Are there Leading Indicators?

    37

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    Software SURVEY ANSWERS MAPPED TO CMM - TMM Model

    38

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    Results

    39

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    Results (contd)

    40

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    Key Excellence Indicators: WorkforceFocus

    Recognition of your workforce as internal

    customers Strong commitment to workforce satisfaction,

    motivation, well-being, and morale

    Reward system related to key organizationalchallenges and organizational performance

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    4242

    OSHA Recordable RatesActual to Date = 2.4

    Overall Goal = 4.0Rate is per 100 associates / year

    1.60.02.04.06.08.0

    10.012.0

    WEST

    1.4

    0.02.04.06.08.0

    10.012.0

    CENTRAL

    4.6

    0.02.04.06.08.0

    10.012.0

    EAST

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    Key Excellence Indicators: WorkforceFocus

    Commitment to training, education, and

    development Links between individual and organizational

    learning

    Empowered workforce members

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    Transforming Culture Goal: Provide middle management with the

    skills to begin the transformation toinstitutionalizing continuous improvement

    Why?- Leaders must create the culture

    Middle management leaders are closestto the daily work

    - 4 components to culture Experiences: Foundation of the culture Beliefs: Experiences form the beliefs; beliefs

    people hold about what they should do and howthey should do it drive the actions they take

    Actions: Those actions produce the resultsthey achieve Results: Results achieved from experiences,

    beliefs, and actions produce results, and formthe culture

    Culture

    Experiences

    Beliefs

    Actions

    Results

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    Alignment Experiences, Beliefs, and Actions must be aligned to achieve

    new results

    Avoid saying and doing things that put the culture out ofalignment

    We can more significantly and permanently improve resultsby working at the level of associates beliefs

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    The Vision: Dual Function of Work(Institutionalize Continuous Improvement )

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    IR

    I

    R

    I

    R

    I

    R

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    Managementattention

    Managing Resistance

    Critical mass

    Managementattention

    Forcing Change

    Increasingresistance

    IncreasingcooperationNeutral

    Increasingresistance

    Increasingcooperation

    Neutral

    Early adopters

    Traditional Situation

    Anchordraggers

    "UncommittedMass"

    Strong pull

    from earlyadopters

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    5151

    Key Excellence Indicators: ProcessManagement

    Well-defined product/service, business, andsupport processes

    Focus on work systems and processes that createvalue for all key stakeholders

    Quality designed into products, services, andprocesses

    Focus on continuous improvement, cycle timereduction, innovation, and productivity

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    535353

    Requirements ABCD

    Design ABCD

    Construct ABCD

    Test ABC DDeploy ABC

    Waterfall = One Big Bite

    Opportunity cost ofStaff during project ABC

    B

    u s

    i n e s s

    V a l u e

    Months 1 2 3 4 5

    Scope:ABCD

    Cut D? Ok.Change A,C?Too late.

    How familiar is this?

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    IterationsWaterfall

    Stable requirements

    Established technology

    Few deployment windows

    Can tolerate longer ROI

    Dynamic requirements

    Emerging technologies

    Few or frequent deployment

    Need for faster ROI

    When to use which?

    Effort to fix defects

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    Effort to fix defects

    20 Production

    UAT16

    Enterprise Test

    12

    System Test

    8 Unit Test

    Development Cost to fix increases4

    Tech Design

    Requirements 0

    Lifecyc le Source:NIST

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    S Q D C Board

    Visual Management

    Dayshift 1 23 4

    5 6

    7 8

    9 10 11 12 13 14 15 16

    17 18 19 20 21 22 23 24

    25 26

    April27 28 Green = Safe Day

    Clyde Yarbro29 30 Orange = Near Miss

    Month:

    31 Red = First Aid or.... Recordable Injury

    Owner:

    1 2 3 4 5

    6 7 8 9 10 11

    12 13 14

    15 16 17

    18 19 20

    21 22 23

    24 25 26 27 28 29

    30 31

    1 2 3 4 5

    6 7 8 9 10

    11 12 13

    14 15 16

    17 18 19 20

    21 22 23 24 25

    26 27 28 29 30 31

    S Q D C 6S

    Measure

    Analyze

    Improve

    Safety Quality Delivery Cost 6S

    Counter measures

    Daily6S Audit

    Counter measures

    Counter measures

    Counter measures

    Counter measures

    1 2 3 4 5

    6 7 8 9 10 11

    12 13 14 15

    16 17 18

    19 20 21 22

    23 24 25 26 27 28

    29 30 31

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    5858Slide 58

    Visual Performance Tracking

    Associates track and report theirown performance

    SQDC board is a tool that enablesall to participate

    Countermeasures (improvements)are listed to show problemsolving activities

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    T HE STANDARDIZATIONTOOL

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    Maturity Level Impact

    CMM Level Process Maturity (Characteristic) Rework(% of Total Development)

    Product Quality(Defect Density)

    1 Immature50% or greater Double digit

    2 Project Controlled 25% - 50% Single digit

    3 Defined Organizational Process

    15% - 25% 0.X

    4 Managed by Fact5% - 15% 0.0X

    5 Continuous Learning andImprovement

    5% or less < 0.00X

    Process Maturity vs. Rework Cost and Defect Rate 2

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    6161

    - ISO 9001 (MPTQM *) Requirements

    - The standardization tool- Turns tacit knowledge into articulated knowledge

    * MPTQM (Mail Preparation Total Quality Management Program) combines:

    - Malcolm Baldrige Performance Excellence Criteria- ISO 9001 Requirements

    - Total Quality Management (TQM) Concepts

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    ISO 9001 Standard-The Basics Generic- means that the same standard can be applied to any

    organization , large or small, whatever its product or service, in any

    sector of activity , and whether it is a business enterprise, a publicadministration, or a government department.

    Management system standards- provide a model to follow in settingup and operating a management system. This model incorporates thefeatures on which experts in the field have reached a consensus as beingthe international state of the art.

    The Plan Do Check Act (PDCA) cycle- is the operating principle

    of ISO's management system standards. The Standard-Do-Check-Act (SDCA) cycle- another operating

    principle of ISO 9001, for standardization of processes until changedthrough a PDCA cycle

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    PLANDO

    CHECK ACT

    DO

    CHECK ACT

    Institutionalized Continuous Improvement

    Dual Function of Work

    Improvement Daily

    PDCA & SDCA

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    T HE IMPROVEMENTENGINES

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    The Business Excellence Maturity Model

    Launch, TrainMgt., BuildInfrastructureTrain BB,Initial Projects

    6S, VSM,Lean Cert.,

    Kaizens,expand into

    softwaredevelopment

    RefresherTraining;Improved

    GBtraining;Harvestprojects

    Expandtraining: GB,

    BB, Lean Accelerate

    projects,Material

    LeanInitiative

    BurningPlatformlaunchesBusinessExcellence

    KeyGoals

    Generate Enthusiasm

    Demonstrate Success

    Accelerate Benefit Delivery

    Make Improvement Sustainable

    Align Improvement With Strategy

    2004 2005 2006 2007 2008

    Decision toexpanddeployment

    LSS results linkedto strategies Decision to Lead withLean and Follow withSix Sigma

    Expand to Company WideBasis

    2009Lead with

    Lean,Follow

    with SixSigma;expand

    into clientservices

    6S, VSMdriven

    projects;expand intoother non

    productionprocesses,

    expand leantraining

    Dual Function of Work-DNA

    Shift Responsibilityto Process Owners

    h f

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    6666

    Lean Six Sigma is the Integration of TwoPowerful Business Improvement Approaches

    Lean

    Speed+Low Cost

    Goal- Reduce waste andincrease process speed

    Focus- Identify non-value addedsteps and cause of delay

    Method- Kaizen events

    Lean Speed Enables Six SigmaQuality (Faster Cycles of

    Experimentation/Learning;Simplified Processes)

    Six Sigma

    Variation+Quality

    Goal- I mprove performance on CriticalCustomer Requirements

    Focus- Use DMAIC with Quality tools toeliminate variation/ improve levels

    Method- Management engagement,dedicated Black Belt resources, GreenBelts

    Six Sigma Quality Enables Lean Speed(Fewer Errors Means Less Time Spent

    on Rework)

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    Customer-defined value

    Map andunderstand

    value stream

    Make valuestream

    flow

    Continuousprocess

    improvement

    Goals: Increase productivity Eliminate waste Maximize resourceutilization

    Waste includes Scrap Rework Inspection Inventory Queuing time Transporting materials

    or products

    Redundant motion Anything for which a final

    customer would not want topay

    Leanis focused on the elimination of all nonvalue-adding

    activities and waste from the organizations processes.

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    What Lean Is:

    A methodology for improving cycle times and qualitythrough elimination of waste

    Waste sometimes called muda

    Differentiates between value-added and non-valueadded activities

    Value defined in customer terms

    Lean techniques allow sustained operations withreduced resource and cycle times

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    Focus: Visibility, Velocity, Value Visibility (Transparency, Visual Control)

    Broadens awareness of problems.

    All hands on deck urgency to resolve. Velocity (Flow)

    Concentrate on speed of delivery

    Improve responsiveness to customer demands

    Value (Opposite of Waste)

    Focus on value-added activities

    Remove other (wasteful) activities

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    Value Added Activities

    Something the customer iswilling to pay for!

    Transform raw material orinformation to meet customerrequirements. Transforms form,fit, or function.

    Done right the first time.

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    Non-Value Added Activities(Waste)

    Consume time, resources, space

    No value added to customer Doesnt contribute directly to customer deliverables Not done right the first time

    WANT NEED

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    Conceptualtraining on:

    Project-SpecificTraining

    Measure &

    Analyze CurrentWork Process

    FormulateProcess

    Improvements

    EvaluateImprovements

    Establish New

    StandardProcess

    Operate UsingNew Standard

    Process

    Finalize NewStandardProcess

    Present

    Results andCelebrate!

    Day 4Day 3

    Simulate &Refine

    Improvements

    Day 5Day 4Day 2 Day 3Day 1

    Lean/SixSigma

    StandardOperations

    6S Kaizen

    Methodology Tools &

    Techniques

    Kaizen Breakthrough Methodology

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    What is Six Sigma?

    A metric- Represents 3.4 defects per million opportunities.

    A methodology- Highly disciplined process that focuses on delivering near

    perfect products and/or services. Can be applied to any

    process or product to eliminate defects and their associatedcost, and reduce variation

    A mindset- Designed to focus an entire organization on producing nearly

    perfect products and services that delight customers andrealize higher profits.

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    Six Sigma concentrates on variationreduction by using statisticalmethods to lower process defectrates to less than 3.4 defects per millionopportunities.

    Six Sigma Methodologies: DMAIC -define, measure, analyze, improve, and control DMADV -define, measure, analyze, design, and verify

    Six Sigma

    Si Si P

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    Six Sigma Process

    Formulating the Practical ProblemPhase Question

    Define What do I want to improve? What is the problem statement?

    Measure Whats the best way to measure? Does performance meet expectations? How muchvariation is there?

    Analyze How good is my process today? What is at theroot of the problem? What causes the processto behave the way it does and creates theoutput?

    Improve Whats at the root of the problem? Developsolutions to eliminate or minimize the root causeinfluence on the process and outputs?

    Control How can I sustain the improvement? Whatcontrols can be put into place?

    75

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    l h

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    Recognize a ProjectOpportunity

    Is theSolutionknown?

    JustDo Itwith

    PDCA

    AreSolutionsobvious?

    Workout/Kaizen

    Blitz

    Is it a newproduct orprocess?

    DFSS

    Is theobjective to

    reduce time?

    Is the timebottleneck due

    to defects?

    Lean

    SixSigmaDMAIC

    Selecting the Improvement Engine

    NO

    YES

    NO

    YES

    NO

    YES

    NO

    YES

    YES

    NO

  • 8/10/2019 ALHodlinS

    78/102

    7878

    Key Excellence Indicators: Results

    Tied to

    customer requirements

    key processes

    product/service performance

    strategy and action plansWorkforce needs

    financial and marketplace measures

    governance and social responsibilities

  • 8/10/2019 ALHodlinS

    79/102

    7979

    Key Excellence Indicators: Results

    Tracking of levels and trends

    Linked to organization-level informationand analyses

    Use of comparisons/benchmarks

    Actionable

  • 8/10/2019 ALHodlinS

    80/102

    8080

    Tracking Progress:Strengths and Opportunities for ImprovementProvides operational capability analysis

    Used as input into the strategic planning process

  • 8/10/2019 ALHodlinS

    81/102

  • 8/10/2019 ALHodlinS

    82/102

    8282

    Business Excellence Survey Results

    0

    100

    200

    300

    400

    500

    600

    2005 2007 2009

    Business Excellence Survey Scores

    Business Excellence Survey Scores

    DST Output Confidential

    i All h

  • 8/10/2019 ALHodlinS

    83/102

    8383

    Putting It All Together

  • 8/10/2019 ALHodlinS

    84/102

    ISO 9000 CMMi Six Sigma and Lean

  • 8/10/2019 ALHodlinS

    85/102

    8585

    ISO 9000, CMMi, Six Sigma and LeanHow they relate to the seven Baldrige Criteria Categories

    Th L d hi C

  • 8/10/2019 ALHodlinS

    86/102

    8686

    The Leadership CategoryBaldrige, ISO 9000, Lean, and Six Sigma alldepend on leaders who

    Align financial and human resources Communicate cultural norms Encourage and provide resources Solidify a culture of organizational excellence

    Baldrige addresses the overall leadershipsystem.

  • 8/10/2019 ALHodlinS

    87/102

    8787

    Strategic Planning Category Lean and Six Sigma can be methodologies for coordinating resource use towardorganizational objectives identified using the Baldrige Criteria. Six Sigma provides tools for measuring progress.

    ISO 9000 has standards for measurement.

    EnvironmentalAssessment

    Finalize company-widegoals and strategies

    Finalize departmentstrategies and action

    plans.Vail presentation.

    Align financialbudgets to

    strategic plan

    Align associateaction plans tostrategic plan

    Conduct environmental assessment

    2009 April May June - July Aug - Sept Oct - Dec

    Vision,Principles &

    Mission

    ExternalOpportunities &

    Threats

    CompanyStrengths &Weaknesses

    GoalFormulation

    Action PlanFormulation

    Timelines &Implementation Measurements

    StrategyFormulation

  • 8/10/2019 ALHodlinS

    88/102

    8888

    Customer Focus Category

    Lean environments aim

    for all process steps tobe something forwhich the customer iswilling to pay.

    In Baldrige and Six Sigma, the voice of thecustomer is used to identify areas of neededimprovement.

    Customer-defined value

    Quantification ofcustomer needs is the key.(Voice of Customer)

    Map andunderstandvalue stream

    Make valuestream flow

    Continuousprocessimprovement

    2005 2006 2007 2008 2009(target)

    2009Results

    OverallSatisfaction

    83% 82% 88% 83% 85% 89%

    WouldRecommend

    49% 40% 52% 46% 88%* 92%

    Measurement Analysis and Knowledge

  • 8/10/2019 ALHodlinS

    89/102

    8989

    Measurement, Analysis, and KnowledgeManagement Category

    Six Sigma :is data-driven:

    specific metrics data collection data analysis

    control data

    Lean :measures, analyzes,and reduces waiting time inventory batches process time rework

    ISO 9001: The standardization tool-Turns tacit knowledge into articulated

    knowledge-Enables Knowledge Management

  • 8/10/2019 ALHodlinS

    90/102

    Process Management Category

  • 8/10/2019 ALHodlinS

    91/102

    9191

    Process Management Category

    Processes are interrelated and interdependentsteps along the path to customer satisfaction.

    ISO 9000, Lean or Six Sigmamethodologies are used to Generate standard operating procedures Set specification and control limits Identify explicit corrective actions

    Optimize processes0

    2,500

    5,000

    7,500

    10,000

    12,500

    O-08 N-08 D-08 J-09 F-09 M-09 A-09 M-09 J-09 J-09 A-09 S-09 O-09

    Defects Per Million - 13 Month Control Chart ActualPerformance Threshold 2008

    Average ppmUpper Control LimitLower Control Limit

    R lt C t g

  • 8/10/2019 ALHodlinS

    92/102

    9292

    Results CategorySix Sigma and Lean are data-driven and results-oriented. Their use leads totracking systems (control charts, scorecards, rolled throughput yield charts, etc.) and

    results monitoring in functional business areas where the methodologies are applied.

    0

    2,500

    5,000

    7,500

    10,000

    12,500

    O-08 N-08 D-08 J-09 F-09 M-09 A-09 M-09 J-09 J-09 A-09 S-09 O-09

    Defects Per Million - 13 Month Control Chart ActualPerformance Threshold 2008

    Average ppmUpper Control LimitLower Control Limit

    0

    5,000

    10,000

    15,000

    20,000

    25,000

    30,000

    O-08 N-08 D-08 J-09 F-09 M-09 A-09 M-09 J-09 J-09 A-09 S-09 O-09

    Late Statements Per Million - 13 Month Control Chart Actual Average ppmUpper Control LimitLower Control LimitPerformance Threshold '08-09

    360

    206

    121

    54 42 32 28 27

    34%

    53%

    64% 69%

    73% 76%79% 81%

    0%10%20%30%40%50%60%70%80%90%100%

    0

    100

    200

    300

    400

    Bad or incorrect foldIncorrect statement orientationMultiple inserted or mixed statementsPartial statementRemits rejected by lockboxPoor print qualityWrong remit/insertUnsealed envelope(s) mailed

    I

    0

    100,000

    200,000

    300,000

    400,000

    500,000

    Oct-08

    Nov-08

    Dec-08

    Jan-09

    Feb-09

    Mar-09

    Apr-09

    May-09

    Jun-09

    Jul-09

    Aug-09

    Sep-09

    Oct-09

    All Client Systems

    S ummary

  • 8/10/2019 ALHodlinS

    93/102

    9393

    The Baldrige Criteria focus on organizational improvement and innovationsystems . Six Sigma and Lean methodologies drive waste and inefficiencies out ofprocesses that users of the Baldrige Criteria identify for improvement. CMMi , SixSigma and Lean focus on organizational improvement and innovation processes .ISO 9000 aids in the setting of standardized processes in managementresponsibility, resource management, product realization, andmeasurement/analysis/improvement

    I i d i i

  • 8/10/2019 ALHodlinS

    94/102

    9494

    28 industry patents, including Mail-by-Tray

    All U.S. operation centers MPTQM certified

    IndustryWeek awards

    DALBAR client awards

    Exstream Visionary awards

    Xplor International awards

    3 time recipient of Industry Weeks Top Ten Best Plants in North America

    Innovation and recognition

    S elected results over year period

  • 8/10/2019 ALHodlinS

    95/102

    9595

    S elected results over year period

    Revenue increased by 31%

    Profits increased by 42%

    Business Excellence Assessment usingBaldrige Performance Excellence Criteriaincreased 52% since 2005

    Defects per Million Opportunities decreased by77%

    Late Per Million Opportunities decreased by70%

    Quality and On-Time Delivery performance

    exceed the Industry Weeks Top Ten Plants 4year average

  • 8/10/2019 ALHodlinS

    96/102

  • 8/10/2019 ALHodlinS

    97/102

    9797

    Lean Six Sigma

    DMAIC:

    1. Define2. Measure

    3. Analyze

    4. Improve

    5. ControlLean Thinking-Kaizen

    ContinuouslyImprove the Process

    *

    Relationship Between SDCA and PDCA

    New standard

    C

    SD

    Process Control

    Need for improvement A P D

    C A

  • 8/10/2019 ALHodlinS

    98/102

  • 8/10/2019 ALHodlinS

    99/102

    9999

    Integration: The Dual Function-Institutionalize Continuous Improvement

    PDCA is used at all levels and inall departments to improve localdaily work processes

    This is when ContinuousImprovement is the DNA of theorganization

    c ad s ca

    dp

    newSTD

    c ad s ca

    dp

    newSTD

    c ad s ca

    dp

    newSTD

    c ad s ca

    dp

    newSTD

    c ad s ca

    dp

    newSTD

    c ad s ca

    dp

    newSTD

    c ad s ca

    dp

    newSTD

  • 8/10/2019 ALHodlinS

    100/102

    100100100

    C onclusions Visionary Leadership

    Systems Perspective Linkage and Alignment

    Valuing Workforce Members and Partners

    Management by Fact

    Focus on Results and Creating Value

    The various quality system methodologies are synergisticparts of the system

    Any other takeaways?

    Critical Components, Perfectly Synchronized

  • 8/10/2019 ALHodlinS

    101/102

    101101

    Creating Customer Value and Corporate Growth

  • 8/10/2019 ALHodlinS

    102/102