1. LEAN Six Sigma
LEAN Six Sigma
Introducing the basics of LEAN and
Six Sigma and applying the
techniques in design work
2. Objectives - Education
What is LEAN Six Sigma in 3 presentations.
First presentation to give a general
information about LEAN and Six Sigma,
about quality control, processes, some
statistical and mathematical explanation.
3. Objectives - Education
Second presentation will explain what is
LEAN - how to save money by using simple
techniques like 5S and Value stream map
and as example will be presented system for
organising electronic components - creating
data base, organasing storage area, make
design kits.
Third presentation will be focused on Six
Sigma – DMAIC, cause and efect analysis,
some statistical tools for presenting the
data.
11. What is LEAN Production
LEAN Production
Producing only what is needed, when it is
needed
Pull System - A system of cascading production and
delivery instructions from downstream to upstream activities in
which nothing is produced by the upstream supplier until the
downstream signals a need,
TaktTime - Balance, Predictable Cycle Time
Eliminate all waste
Value Steam
Value Add – Non-Value Add
Reducing parts staying in “Work in Progress” state
One-piece flow or controlled/small batch sizes
13. What is LEAN Production
LEAN Production Benefits
– Major productivity increases
– Reduction in throughput times
– Reduction in inventory
– Improved quality
– Reduced time to market
How much does it cost?
– In many cases, companies replace expensive
equipment with much simpler and cheaper
equipment.
– LEAN production does not emphasize
technology or automation.
15. Tools of LEAN - Competitive
Excellence
Visual Factory
5S
Total Productive Maintenance
Quality Control Process Charting
Process Certification
Mistake Proofing (POKA-YOKE)
Set-up Reduction
Standard Work
Value Stream Mapping
19. What is Value Stream Mapping ?
Value Stream Defined
•The specific activities required to design, order,
and provide a specific product, from concept to
launch, order-to-delivery, and raw material to
finished item in the hands of the customer.
Each step in the value stream is either:
1.Creating value
2.Creating no value, but unavoidable due to
current technologies and production assets
3.Creating no value and immediately avoidable
21. What is Value Stream Mapping ?
Value add Activity
That which the customer will pay for.
Work done right the first time.
Non-Value Add or Waste
Process/operation that takes time and resources
but do not add value to the product or service.
23. What is Value Stream Mapping ?
Purpose of Value Stream Mapping / Analysis
Arrive at a common understanding of the current process
The relationship of process steps
The relationship of material and information flows
А true picture of the process
Define the baseline to measure improvements against
Recognize that lots of waste exists
�Define a vision of the future process (12 month outlook)
Identify opportunities for improvement and establish
common leadership objectives
Design an implementation plan for process improvements
Quick fixes
Projects
26. KAIZEN
Simply put, Kaizen is “Continuous Improvement”,
derived from the Chinese , but also used by the Japanese
to explain a gradual and orderly continuous improvement
for anything.
Pioneered by the Toyota Motors Corporation: Taiichi
Ohnoalong with Shigeo Shingo further developed and
structured Kaizen versions at Toyota.
Kaizen is a effective tool for driving continuous
improvement activities, and it doesn’t cost lots.
Kaizen is about driving lots of small incremental
improvements on a regular basis.
It takes dedicated work and commitment
Benefits occur over time
Shows bottom line results - A benefit to both Profitability
and Quality
35. 5S - Sort, Simplify, Shine, Standardize, Sustain
Standardize the work place to prevent disorder, chaos,
disorganization, and unclean conditions.
Should leave no doubts about how something is done,
who does it, and when it happens – keep
records...Document changes and share information
with others.
What are the objectives?
Ensure quality products at the source.
Prevent problems beforethey arise.
39. 5S in BENETEL
5S – How to make our life easyer?
Creating the component data base:
- new part number system – with field for:
The type of component,
The value,
Parameters,
Manifacture part numbers (MURATA,
Johanson, Coilcraft...)
Place – where stay in the rack
- storage area
- designers kits – with most frequently used
components like resistors, capacitors, inductors
