PRESENTED BY THE UNIVERSITY OF TEXAS-SCHOOL OF PUBLIC HEALTH
This material was produced under grant number SH-22316-SH-1 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S.
Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.
Overview of Lean Six Sigma
Upon completion of this course, the participant will be able to: • Define Lean Six Sigma• Compare Lean with Six Sigma to process improvement• Select appropriate phases to apply Six Sigma DMAIC Methodology• Outline the integration of Lean and Six Sigma to process improvement
Learning Objectives
How Will Lean Six Sigma Affect You?
Enables each of us to lead change by challenging what we do and how we work
Why am I doing what I am doing? Is it adding value to my client and Fannie Mae?
Gives us practical metrics to evaluate success Involves you and your team members in creating solutions
How does my work affect my customer? How does my work affect other teams (up and down stream)? How can I do it better?
Provides new skills for life!
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The Lean Six Sigma methodology will lead to more meaningful jobs (that bring value to our patients) in a better team environment!
What is Lean Six Sigma?
Lean Six Sigma is A common improvement methodology to impact the overall
business Fact-based decision making Focused on minimizing waste and variation
Focused on strategic business priorities, including the voice of the customer
Works best for narrowly scoped projects Dedicated resources with clear accountability
Quantified project benefits Emphasis on sustaining the gains! Demonstrated track record of success across industries
Lean Defined… Six Sigma Defined…
Lean optimizes the process design
Came from process efficiency practices at Toyota
Addresses the fundamental flow of a process
Is a philosophy of continuous improvement that finds and reduces Wasteful or unnecessary activities Illogical or inefficient process
sequencing Rework Excessive cycle times
Lean improvements are typically logical and easy to understand
Lean addresses problems that are a “mile wide and an inch deep”
Six Sigma is a process improvement methodology addressing defects which arise due to variability in process execution
A defect can be any missed target or nonconformance to standard Six Sigma seeks the causes of variability Six Sigma projects often apply deep analysis Solutions are not readily apparent
Lean VS. Six Sigma to process improvement
VS
Lean= efficient process design Six Sigma= defect-free process execution “Six Sigma” is a metric used to evaluate the process
Example: A “defect” is the failure of any process to deliver the intended
result 3.4 defects per million opportunities for defects (99.9997%
good)
“Lean Six Sigma” Defined
Identifying waste and making it visible is the first step
Elimination of waste . . . Including unnecessary process steps
1. Specifying the value of the process
2. Identifying the value stream for each process
3. Allowing value to flow without interruptions
4. Letting the customer pull value from the process
5. Continuously pursuing perfection
The 5 Principles Of Lean
Lean techniques are used to reduce unnecessary steps, eliminate rework, save time, save cost and extend capacity of valuable resources by:
Process Focus Of Lean Six Sigma
Inputs (X1, X2 . . Xn)Independent
CauseControl
OutputDependent on inputEffectMonitor
Lean focuses on optimizing process design
X YProcessY = f(x)
Dynamics Of Execution Strategy
Define Phase
Measure Phase
Analyze Phase
Improve Phase
Control Phase
Optimized Process
10 – 15 Xs
8 – 10 Critical Xs
4 – 8 Critical Xs
3 – 6 Critical Xs
30 – 50 Xs (or more!)
KPIV = Key Process Input Variable
Business Need
Y
X
Y = f(X)
Sustain!The
Funn
el E
ffect
DMAIC Process
DefineBusiness
Need
Measure Y
Analyze X
Improve Y = f(X)
Control Sustain!
The DMAIC Process Improvement Model
1DEFINEWho are the customersAnd what are their priorities?
2MEASUREHow is the process performing and how is it measured?
3IMPROVEHow do we remove the causesof the defect?
4ANALYZEWhat are the important causes of the defect?
5CONTROL
1. Define Phase
• Confirm Process Requirements (voice of customer)• Validate the definition of a “defect”• High level process mapping• Charter the project using metrics aligned with business
objectives• Execute “quick wins” when possible
Confirm the business case for working the project
2. Measure Phase
• Collect baseline data on project metrics (from the Define phase)
• Verify integrity of baseline data for project metrics• Look for patterns in the data• Quantify the historical performance• Begin detailed process mapping
Before trying to “fix” the problem, confirm that you can measure the process
3. Analyze Phase
• Apply non-statistical techniques to brainstorm potentially critical Xs which may be driving variability in the project metrics (again from the Define phase)
• Apply statistical techniques to investigate the potentially critical Xs
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Only after completing Define and Measure do you begin the detailed investigation into Critical Xs
4. Improve Phase
• Develop potential solutions based on Critical Xs from the Analyze phase
• Pilot the “best fit” solution• Plan for full-scale implementation
Solutions are based on findings from the Analyze phase
5. Control Phase
• Develop Control Plan• Implement full-scale improvement• Implement controls• Train personnel and hand-off control plan to Management
Final solution is robust and becomes ingrained in the operation.
Define
Measure
Analyze
Improve
Control
1&2PHASETools:• Voice of Customer (VOC) Analysis• Process Mapping• Value Stream Mapping
The DMAIC Process with Tools
DAY 1
Define
Measure
Analyze
Improve
Control
3&4PHASETools:• FMEA• Quick Wins 5S• The 8 Wastes
The DMAIC Process with Tools
DAY 2
Define
Measure
Analyze
Improve
Control
5PHASETools:• Controls Plans• Lean Visual Controls• Mistake Proofing (Poke Yoke)
The DMAIC Process with Tools
DAY 3
Integrating Lean And Six Sigma
No matter the nature of a project, value and objectives must be understood
No matter the nature of a project, the process must be measurable
Depending on the nature of a project, Lean tools, Six Sigma tools, or a combination may be best to solve the problem
No matter the nature of a project, the final solution must be controlled.
Define
Improve
Control
Measure
AnalyzeLean Tools
SIX SIGMA TOOLS
Summary
• Lean Six Sigma gives you practical metrics to evaluate success in the context of corporate objectives.
• Lean Six Sigma is used to reduce unnecessary steps, eliminate rework, save time, save cost and extend capacity of valuable resources.
• Five phases of DMAIC process is define, measure, improve, analyze, and control.
Thank You