Practical Implementation and Application of Lean Six Sigma Tools in Your Organization
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Practical Implementation and Application of Lean Six Sigma Tools in Your Organization

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Practical Implementation and Application of Lean Six Sigma Tools in Your Organization Practical Implementation and Application of Lean Six Sigma Tools in Your Organization Presentation Transcript

  • Practical Implementation and Application of Lean Six Sigma Tools in Your Organization Thursday, December 2, 2004 Presented by: Ginny Moszkowicz Global Mailing Systems Pitney Bowes, Inc.
  • Implementation of Lean 6 Sigma
    • Analyzing the implementation of the tools needed from Lean and Six Sigma
    • Deploying Lean tools within a Six Sigma environment
    • Knowing when to apply which tools
    • Reaping the benefits by tracking and reviewing projects
  • Choosing Tools from Lean and Six Sigma Pull System Takt Time Kaizen Events Kanban Value Stream Mapping Visual Workplace 5S Six Sigma Lean Process Mapping Pareto Charts Measurement System Analysis Hypothesis Testing DOE FMEA Control Charts TPM Fishbone JIT
  • Deploying Lean in a Six Sigma Environment
    • Define Lean as an expansion of the tool set not a replacement by a new program
    • Decide if Black Belts will be trained in Lean tools or if there will be separate Lean Experts
    • Capture case studies of applications of Lean in the business
    • Focus right tools on the right problem
  • Knowing when to apply which tools
    • Determine root cause
    • Eliminate steps / rework
    • Optimize process
    • Control and Standardize
    What is the problem? Variability Reduction Cycle-Time Reduction Waste Elimination
  • Track and Review Projects Define Problem Control Review Analyze Review Measure Review Define Review Improve Review Audits to sustain standardization Checklists during implementation After Photos Before Photos
  • Case Study I: Reduce Cycle Time of Stripping Parts from Remanufactured Equipment Open Open BEFORE AFTER Parts Repair Pick & Pack
  • Lessons Learned
  • Case Study II: 5S of Manual Package Sortation S ort - Remove labels from rollers, keyboards, floors S hine - Clean motors to inspect, remove dust, sweep S et in Order - Label min/max quantities of supplies S tandardize - Layout of each scan station identical S ustain - Audits by operations people daily, weekly Problem: Reduce the number of safety incidents in package Sortation operation with belt driven conveyors Result: a 75% reduction in # Safety incidents
  • Lessons Learned
  • Case Study III: Reduce cycle time of monthly financial close 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
    • Root Cause analysis:
      • Fishbone diagram
      • Pareto charts
      • Run chart
    • Standardized work
    • Operational definitions
    • Action Item Registers
    • Audits to Standardize
  • Lessons Learned
  • Q & A Session Contact information: [email_address] 203-351-6574 http://www.pb.com