Lean Six Sigma
Lean Thinking
1987
1996
2005
2020
o Theoryo Maths & Statso Principleso Mindseto Tools & Techniqueso DMAIC Project Managemento Structureo Cultureo Philosophy
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Roles within Lean 6 Sigma
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Lean Basics
External entity that buys the product or
service ( pays the invoice )
Internal support functions within your own organisation
RegulatoryBodies you have
to report to / comply with
VA
NNVA
NVA
Six Sigma Basics
Y = f (Xi) To control Output Y
All critical inputs must be identified& Controlled
Only then will we have ”control” of theVariation in and performance of a process
The problem with Averages
20, 30, 50, 70, 80.
Standard Deviation
1, 2, 3, 4, 5, 6, 7, 8, 9
Standard Deviation
1, 2, 3, 4, 5, 6, 7
-3, -2, -1, 0, +1, +2, +3
Standard Deviation
Averages – Find the best route to work every dayYou record the travel timeover a 2 week period
Route A has an averageOf 20 mins
Route B has an averageOf 19 mins
Which Route do you pick ?
Averages – Find the best route to work every day
Lower SigmaLower Variation
And that number is 99.9997%
DMAIC Basics
Project Methodologies
PMI’s PMBOK
Prince 2
Agile & Scrum
Lean / DMAIC
DMADV / DFSS
Project Selection
• Project Selection
Must align to strategy of the business
Must bring potential benefits
Must have a clear sponsor / champion
Timebound (> 5Mins < Infinity ) 1 to 6M
Potential Projects
Potential Projects
T
E
C
D
R
Q
Potential Projects
• Project Selection
Document Basics
• Project Selection
• Project Charter
• SIPOC
• Stakeholder Management Plan
• VOC, VOP, CTQ Inputs established
• Process Focus – Process Map
• Team & Change Management Plan / RACI
• SIPOC
A high level map which helps to visualise the “voice of the customer” and begin to see the relationship between
Inputs & Outputs
Value Stream Mapping - Measurements
• Process Time PT Timeline
• Waiting Time WT Timeline
• Leadtime LT Timeline
• Time Metric % Activity Ratio ( PT / LT )
• Quality Metric % RTY Rolled Throughput yield
Activity Ratio :
Considers total Lead time of a process as a combination of
Process time ( useful ) & Waiting Time ( waste )
LT = PT + WT
A:R = PT / LT
PCE = Process Cycle Efficiency
Considers the Leadtime of a process as being a combination of Value Add ( VA ) + Non-Value-Add ( NVA ) + Necessary-Non-Value-Add ( NNVA ).
PCE examines the relationship between VA and LT.
LT = VA+NVA+NNVA
PCE = VA/LT
Gate Reviews
Benefits of the Gate Review
• Provides high-impact coaching opportunity• Helps establish key deliverables• Relates to Milestones in the project plan• Prevents project rework• Prevents false starts• Generates buy-in• Provides formal status reporting• Highlights risks, issues, resource needs• Shares Best Practices• Manages EHS impact
Structure of a Gate Review
•Project Charter – highlight any changes•Project benefit update•Follows the DMAIC roadmap•Expect to spend 30-60 minutes per phase•1/3 project presentation•2/3 questions and discussion
Gate Review Attendance
Initially, face-to-face meetings or a conference call/teleconference is recommended.
Black Belt/Green Belt…………………….RequiredProject Sponsor…………………………..RequiredProcess Owner …………………………..Required (if not = Project Sponsor)
Project Team ……………………………..RequiredStakeholders ……………………………SuggestedCI Director or CI Champion ……..RecommendedValue Chain Partners …………………….Optional
DEFINE:
CharterSIPOCStakeholder MgmtTeam selectionRACICurrent State MapVoice of Customer
MEASURE:
Data TypesMSADPMOFTYRTYOEEActivity RatioPCETAKT TimeProcess MapsCp / Cpk
ANALYSE:
Hypothesis TestAD TestANOVAMultiVary StudyT-TESTPareto Run ChartsControl ChartsIsikawa5 W’s5 WhysFMEAPICK ChartDOEMeasures Central TMean / Mode / MedianRangeQuartilesIQR
IMPROVE:
Kaizen5-SSMEDKanBanPoka YokeVisual managementANDONGEMBATPM
CONTROLS:
Standard WorkFuture State MapAuditsKPI’sControl ChartsQuality PlanResponse PlanReward & Recognize
KanBan
Kaizen
KAIZEN Event
A3 Basics
A3 & PDCA Cycle
Describe the Current state What are we trying to solve.
( PLAN )
Background & Support Data( PLAN )
Set Goals and Targets.Define what success looks like
( PLAN )
Implement the Countermeasures( DO )
Follow UP ( Check )
Perform Root Cause Analysis( PLAN )
Design Counter Measures( PLAN )
Follow UP ( Act )
Plan
DO
Project Leadtime
Do Check Act
Project Leadtime
▰ A common Format
▰ A single sheet
▰ 7 Blocks
▰ Based on PDCA Cycle
▰ Focus on understanding
▰ Advantage of planning
What is A3
Foundations
Behaviours
Artefacts