Process Improvement Workshop
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Process Improvement Workshop

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Process Improvement Workshop Process Improvement Workshop Presentation Transcript

  • Process Improvement Workshop Scott Miller [email_address] 937-781-1068 Dan Dupree [email_address] 937-781-1061 Learn. Perform. Succeed.
  • Workshop Objectives
    • Philosophies
    • Tools
    • Applications
    • Soft Skills
  • Process Improvement
    • Many complementary philosophies.
    • Lean emphasizes minimizing waste and adding value for the customer
    • Six Sigma emphasizes minimizing variation and eliminating defects
    • Theory of Constraints emphasizes identifying and removing bottlenecks
  • Keys to Successful Implementation
    • Journey Mindset
    • Visible Leadership Support
    • Mutual Trust
    • Aligned Reward System
    This is a Culture Change
  • Process Defined
    • Any activity that takes inputs, performs actions on the inputs, and results in outputs
    Process Action
    • Inputs
    • Materials
    • People
    • Equipment
    • Data
    • Outputs
    • Product
    • Service
  • Three Views of a Process
    • Policy (documented)
    • Leadership View as applied
    • What is really happening
  • Value Stream Analysis (a useful tool)
  • Define the Boundaries
    • What is the process?
      • Where does it start?
      • Where does it end?
    • What do you control?
    • What can you influence?
    • What do you need to adapt to?
    Depends on your perspective
  • Value Stream Mapping
    • Define the boundaries
    • “ Walk” the process
      • Identify tasks and flows of material and information between them
    • Gather data
      • Identify resources for each task and flow
    • Create the “Current State” map
  • Analyze Current Conditions
    • Identify value added
    • Identify waste
  • Voice of the Customer
    • What does the customer want?
    • What will the customer trade resources to get?
      • Money
      • Time
      • People
    • Not what we say we can deliver because of our current approach
  • Value Defined
    • Value-Added Activities
    • Transforms or shapes material or information
    • Customer wants it
    • Done right the first time
    • Non-Value Added But Required
    • No value created but required by current technology
    • No value created but required by current thinking
    • No value created but required by process limitations
    • Waste
    • Consume resources but create no value for the customer
    • Pure waste
  • Eliminate Waste
    • Types of Waste
    • Defects
    • Over Production
    • Transportation
    • Movement
    • Waiting
    • Inventory
    • Over Processing
    • Lost Creativity
  • Lean Emphases Resource distribution Opportunity for improvement by reducing waste and creating additional value Value Waste Initial Process Value Waste General Process Reduction Reduce all processes by 25% Waste and Value Both Decrease Waste Only Reduction Value Waste Target & Reduce Waste Maintain Value Value Maintained Resources Decrease Value Creation Value Waste Apply Resources to Create More Value Value Increased Resources Focused
  • Visualize “Ideal State”
    • What if there were no restrictions?
    • Doing what you’ve always done and expecting different results
    INSANITY
  • The MindShift Model Extracted from The 7 Levels of Change by Rolf Smith1997 Do Different Mindshift Different Results Think Different Mindshift Think About Thinking Mindshift
  • Create “Future State” Map
    • Change the process
    • Eliminate waste
    • Maximize value
  • Change
    • Up ‘Til Now….
    • From Now On….
  • Value Stream Mapping
    • Define the boundaries
    • “ Walk” the process
      • Identify tasks and flows of material and information between them
    • Gather data
      • Identify resources for each task and flow
    • Create the “Current State” map
    • Define the value
    • Analyze current conditions
      • Identify value added
      • Identify waste
    • Visualize “Ideal State”
    • Create the “Future State” map
      • Change process to eliminate waste and maximize value
    • Develop action plans and tracking
    • ositive
    • nteresting
    • hallenges
    P I C
  • LEVELS OF CHANGE
    • LEVEL 7: Breakthrough-Doing things that can’t be done
    • LEVEL 6: Different-Doing things not done before
    • LEVEL 5: Adapting-Doing things other people are doing
    • LEVEL 4: Cutting-Doing away with things
    • LEVEL 3: Improving-Doing things better
    • LEVEL 2: Efficiency-Doing things right
    • LEVEL 1: Effectiveness-Doing the right things
    Extracted from The 7 Levels of Change by Rolf Smith1997
  • Lean and Six Sigma
    • Lean and Six Sigma are complementary process improvement philosophies.
      • Lean emphasizes minimizing waste and adding value for the customer
      • Six Sigma emphasizes minimizing variation and eliminating defects
  • Statistically Speaking…
    • Variation is the difference between the actual value and what that value was expected (or desired) to be.
    • The Standard Deviation (Sigma (  )) is a quantitative measure of the variation of individual data items about the mean (expected value) of those items.
    • People notice variation.
  • 1 part per billion falls outside limits 1,350,000 parts per billion fall outside limits In this example, the same number of occurrences are measured. The top curve represents a 6  process, the lower curve represents a 3  process The lower curve (red) represents a process with a standard deviation of 8 units. The specification limits for this represent a 3  process The upper curve (blue) represents a process with a standard deviation of 4 units. Since variation is reduced compared to the lower curve, within the same specification limits, this is a 6  process Specification limits (the values defining the range of acceptable quality)  = 4 -24 +24  = 8 2  1  3  4  5  6  -5  -6  -4  -3  -2  -1  2  1  3  4  5  6  -5  -6  -4  -3  -2  -1  -24 +24 Mean
  • 5S Overview
    • Simplify
    • Shine
    • Sort
    • Standardize
    • Sustain
    • Safety
  • DAU Continuous Learning Center
    • https://learn.dau.mil/html/clc/Clc.jsp
    • select the "Course Information & Access" link.
    • CLE 004, Introduction to Lean Enterprise Concepts
    • CLE 008, Six Sigma: Concepts and Process
    • CLE 007, Lean-Six Sigma
    • CLE 001, Value Engineering.
    • CLE 015, Continuous Process Improvement Familiarization.
  • Thank you for Participating Scott Miller [email_address] 937-781-1068 Dan Dupree [email_address] 937-781-1061 Learn. Perform. Succeed.