V o lu m e 1 , Is s u e 1
ww w. 6 s i g m a. u s
S I X S I GM A / L EA N F LOW F eb r u a r y 2 0 0 3
INSIDE THIS ISSUE:
Six Sigma 2
Six Sigma Belts 2
Six Sigma or 6 Sigma is an
integrated, disciplined, proven
Six Sigma Projects 2
approach for improving meas-
urable results for any organi-
Lean Flow 3
zation. The Six Sigma method
and message is literally im-
Lean Flow Roadmap 3
proving our lives. SixSigma.us
has developed a number of
About Us 4
unique processes to assist
Product Offerings 4
"Business Process Charting".
There are excellent examples
of Six Sigma success emerg-
ing from Hospitals, Doctor's
Special points of inter- Offices, City Government
est: and IT. In addition educa-
tional institutions are incorpo-
• Overview of Six Sigma rating Six Sigma into their
course curriculum. Actual Six Sigma Black Belt Course
• Overview of Lean Flow
No matter what the organiza-
• About Us tion size, whether for profit or Six Sigma is an integrated, that will produce measurable
non-profit, whether private or disciplined proven approach business results. For exam-
government, you should be for improving business per- ple GE Capital saved $2 Bil-
considering Six Sigma to im- formance. lion in 1999 using Six Sigma.
prove your performance. To
benefit from the Six Sigma Six Sigma is management Six Sigma is based upon im-
process, you need only “a methodology driven by data. proving processes by under-
problem with an unknown standing and controlling varia-
solution”. tion, thus improving predict-
Six Sigma focuses on projects ability of business processes.
L E A N F L OW
Lean Flow is a proven meth- Lean Flow can be applied to Lean Flow implementation will
odology to eliminate waste in almost any manufacturing or help identify your highest
any area of your business, administrative process, and is impact Six Sigma opportuni-
bringing together the best most effective when done ties. Almost every process
elements of TQM, Just in throughout the organization. improvement made with a
Time, and various Lean ap- properly chosen Six Sigma
proaches. project will make it easier to
Lean Flow is a natural com- achieve optimum flow.
plement to Six Sigma.
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Six Sigma is not just training. Six Sigma Champions Master Black Belt (MBB)
Each participant called a Business Leaders who lead To achieve self-sufficiency an
“Belt”, either Black or Green, Six Sigma by sponsoring pro- organization needs to develop
is required to have a leader- jects are called “Champions”. future leaders into MBBs.
ship approved project prior to These are your top full-time
training. Champions are trained in the
essentials of the Six Sigma Six Sigma experts, who will
Methodology focusing on help with project selection,
selecting the projects mentor other Belts, and lead
that are aligned with training. MBBs are selected
business goals. from successful Black Belts
for additional training.
Champions must select
and mentor Six Sigma Six Sigma Belts
project leaders called Belts are Six Sigma project
“Belts”. Champions must leaders who receive training
support, align and inte- in the Six Sigma roadmap.
“Six Sigma is not just grate the Six Sigma Each week of training is sepa-
Launch into their organi- rated by one month to allow
training. Each zation. the Belt to align project pro-
participant called a These are Six Sigma Belts. Six Sigma
projects have project leader called belts.
gress to the training.
“Belt” is required to
have a leadership
S I X S I G M A B E LT S
approved project prior to
training.” Six Sigma Black Belts Six Sigma Green Belts Six Sigma Yellow Belts
Black Belts are project lead- Green Belts are project lead- Yellow Belts are project team
ers who receive four weeks of ers who receive two weeks of members who assist and lead
training focusing on the Six training on the Six Sigma different aspects of Six Sigma
Sigma Roadmap and exten- Roadmap and essential ele- projects. It is best for Yellow
sive statistical methodologies. ments of statistical method- Belts to attend a two day
Successful Black Belts nor- ologies supporting Six Sigma project training and kick-off
mally dedicate at least 75 projects. Successful Green session lead by a Black Belt.
percent of their time to a four Belts are able to allocate 50 The Kick-Off meeting is a key
to six month Six Sigma Pro- percent of their time to their way to get project ownership.
ject. four to six month Project.
SIX SIGMA PROJECTS
“A problem with an unknown scoped so they can be com- must be documented upon
solution” pleted in 4 to 6 months. All completion with savings and
Projects must be aligned to Six Sigma pro- signed off by a
business priorities and se- jects must fol- representative of
lected by business leaders. low the Six finance.
Depending on the organiza- Not all Six Sigma
Define, Meas- projects need to
tion, projects should expect to ure, Analyze,
deliver annual savings of at save money, but
Improve, Con- all must be seen
least $100,000 for Black trol or DMAIC
Belts and $50,000 for Green as imperative to
Belts. Projects follow a structured the organiza-
All projects DMAIC process. tional leaders.
The projects should be
S ix S i g ma / L e a n F l o w Page 3
L E A N F L OW
There are as many different erate long-lasting results.
approaches to Lean or Flow
as there are consultants. Pro-
ponents of each style will At the other extreme is a
eagerly tell you that theirs is massive data collection
the only way. There are basic and flow analysis effort
concepts that apply to all that takes one to two years
processes. We prefer to rec- before you make any ac-
ognize that each business is tual change. This can give
unique, and there is no ‘one you a tremendous wealth
size fits all’ solution. of information about your
processes. However, most
of our clients prefer to see Lean Flow is for all organizations.
The simplest versions of lean results sooner than this
involve little more than a approach allows. on facts, not opinions. The
quick look around followed by amount of data required will
an immediate re-arrangement
of the process – based mainly We believe the right answer depend on the nature and “Lean Flow is a natural
is somewhere in between. It condition of the processes.
on gut feel. While this pro- complement to Six
duces change very quickly, is critical to do enough data
collection and analysis to
only occasionally does it gen-
optimize the process based Sigma. The data
gathered in your lean
L E A N F L OW R OA D M A P flow implementation will
help identify your highest
Organize and Begin Process Data Collection egy (Customer Driven Capac- impact Six Sigma
(Define) (Measure) ity), Create Expanded SOPs
Identify Current Quality Crite-
Establish Steering Committee Document Process Maps and
and write Charter and Identify Product Flows, Gather Prod- ria and Related Issues process improvement
Champions, Identify Overall uct to Process Relationships
Project Leader, Establish Pro- Data – Time and Quantities,
Plan Process Layout
made with Six Sigma
ject Teams and Leaders, Hold Quantify Rework, Scrap, Op-
Initial Training and Kickoff tional Flow Paths, and Per-
(Analyze) will make it easier to
Meetings, Define Metrics and centages, Define Design Vol- Analyze Value Added and
Determine Baselines umes Tied to Business Strat- Sequential versus Parallel achieve optimum flow.
Activity, Identify Process
L E A N F L OW R OA D M A P
Families, Calculate Takt Time sors and Direct to Strategic Sup-
and Resource Requirements Labor Employ- pliers.
Define Materials and Kanban ees, Implement Maintain Ro-
Requirements, Define Work Materials and
bust Lean Flow
Groupings and Operational Kanban Strat-
egy, Physically Daily Operation
Definition, Create Optimized (Control)
Process Flow and Validate Change Process
Paper Line Design, Review Layout, Ongoing Training
Future Capability versus Busi- Implement Em- Lean Flow is not just for manu- and Reinforce-
ness Strategy ployee Flexibility facturing, service and financial. ment Plans, with
and Training Employee Certifi-
Physical Change (Improve) cation, Verify
Finalize Process Documenta- Visual Methods Sheets, Verify Training and Use of Method
tion, Train Front Line Supervi- Flow Meets Expectations Link Sheets at Each Operation
w w w. 6 s i g m a. u s SixSigma.us or 6Sigma.us is supporting organizations implementing Six Sigma and
Lean Flow Statistically based Improvement Methodologies. We also offer courses in statis-
tical methods and MINITAB.
We are a group of consultants that pride ourselves on not being typical consultants. We
have years of experience working in real companies facing real problems, yet still making
real business process improvements happen.
We have experience in a variety of organizations including, Medical, Manufacturing,
Product Development, Services and even State Government. Companies experience in-
cludes 3M, American Standard, Dell, Ford, HP, Maytag, Nokia and Intel .
Our consultants are highly rated instructors well versed in adult learning principles. They
have experience deploying and developing improvement specialist in over 25 countries.
“Helping People We are Six Sigma and Lean Flow knowledge transfer specialists with deployment experi-
Solve Problems with ence in over 25 countries. We offer Six Sigma Yellow Belt through Master Black Belt
Unknown Solutions” certification, Lean Flow Master Certification, 20 focused courses, college credit available.
SixSigma.us provides a full offering of ser-
at Breakthrough vices and courses to lead or support your
Organizational Readiness Assessment
Consulting and project support with con-
sultants with extensive experience
Six Sigma Courses and Lean Flow courses
from overview to advanced topics.
• 10 Day Green Belt
Peter Peterka, Lead Six Sigma Consultant, in Sofia
• 20 Day Black Belt Bulgaria during a Black Belt Wave in 2002.
• 10 Day Master Black Belt
• Minitab for Six Sigma Belts
Mastery and Personnel Development.
Lean Flow courses from overview to ad- Our specialty is custom designing an overall
vanced topics. program for your business. This approach
lets you start seeing results quickly, and also
• 5 Day Lean Flow Six Sigma develops a carefully chosen team of your key
• 10 Others Courses to Support personnel to be Masters of the Six Sigma
Lean Flow Implementation and Lean Flow process.