Six Sigma Lean (SSL) Integration, Tools & Techniques Anand Subramaniam

“ Remember : If you do what you’ve been doing, you’ll get what you’ve been getting.” - Source Unknown

“ Remember : If you do what you’ve been doing, you’ll get what you’ve been getting.”

- Source Unknown

Six Sigma Lean (SSL) Lean Focus – Flow Goal – Reduce waste and increase process speed Focus – Bias for action Method – Kaizen events, Value Stream Mapping, process balancing, constraint identification, mistake proofing Enablers - Lean Speed enables Six Sigma Quality Six Sigma Focus - Problem Goal – Improve performance on Customer CTQs Focus – Use DMAIC with TQM tools to eliminate variation Method – Management engagement, 100% dedicated as Champions and Black Belts Enablers - Six Sigma Quality enables Lean Speed Compliment each other

Lean

Focus – Flow

Goal – Reduce waste and increase process speed

Focus – Bias for action

Method – Kaizen events, Value Stream Mapping, process balancing, constraint identification, mistake proofing

Enablers - Lean Speed enables Six Sigma Quality

Six Sigma

Focus - Problem

Goal – Improve performance on Customer CTQs

Focus – Use DMAIC with TQM tools to eliminate variation

Method – Management engagement, 100% dedicated as Champions and Black Belts

Enablers - Six Sigma Quality enables Lean Speed

What is SSL Methodology ? Starts with the “Voice of the Customer” Overall Process Improvement Waste Reduction Cycle time reduction Eliminate Process Variation Minimise Resources requirements From Design, Make, Market - To delivery of a service and / or product to customers

Starts with the “Voice of the Customer”

Overall Process Improvement

Waste Reduction

Cycle time reduction

Eliminate Process Variation

Minimise Resources requirements

From Design, Make, Market - To delivery of a service and / or product to customers

SSL – Methodology Integration SPEED QUALITY Lean Six Sigma Huge difference between “Lean” & “Six Sigma” tools DEFINE IMPROVE CONTROL MEASURE ANALYSE SPECIFY VALUE FLOW PERFECTION UNDERSTAND DEMAND LEVEL

Why Integrate Both? Increases customer satisfaction Requires a different system model Improves profitability & competitive position Requires implementation & sustaining plans

Increases customer satisfaction

Requires a different system model

Improves profitability & competitive position

Requires implementation & sustaining plans

SSL – Problem Solving Approach Stop Stop Stop Tollgate Review Tollgate Review Tollgate Review Tollgate Review Tollgate Review Stop Stop

What is required Get management commitment Assess the operation & understand the process using a Value Stream Map (product families & production data) Identify lean improvements & Kaizen without automation Implement lean improvements using VSM plan Identify processes requiring Six Sigma analysis Analyse, eliminate, and control variation Start the cycle again

Get management commitment

Assess the operation & understand the process using a Value Stream Map (product families & production data)

Identify lean improvements & Kaizen without automation

Implement lean improvements using VSM plan

Identify processes requiring Six Sigma analysis

Analyse, eliminate, and control variation

Start the cycle again

SSL – Tools & Techniques DEFINE IMPROVE CONTROL MEASURE ANALYSE SPECIFY VALUE FLOW PERFECTION UNDERSTAND DEMAND LEVEL Voice of the Customer Competitive Benchmark Project Definition Value of Cycle Time PIP Management Process RACI Value Stream Mapping LSS Metrics Multi-Voting Techniques Pareto Charts C&E/Fishbone Diagrams FMEA Check Sheet Run Charts Control Chart Cp & Cpk Complexity analysis Multi-Vari Box Plots Interaction Plots Regression ANOVA C&E Matrices FMEA Brainstorm Affinity Benchmark Kaizen Pull Systems Stratification Standardise Setup Reduction TPM, 5S Process Flow Line Balance DOE Hypothesis Testing Check Sheet Run Charts Histograms Scatter graph Control Chart Visual Cntl Poka-Yoke Pareto Chart Interactive Reviews Control Measures

Voice of the Customer

Competitive Benchmark

Project Definition

Value of Cycle Time

PIP Management Process

RACI

Value Stream Mapping

LSS Metrics

Multi-Voting Techniques

Pareto Charts

C&E/Fishbone Diagrams

FMEA

Check Sheet

Run Charts

Control Chart

Cp & Cpk

Complexity analysis

Multi-Vari

Box Plots

Interaction Plots

Regression

ANOVA

C&E Matrices

FMEA

Brainstorm

Affinity

Benchmark

Kaizen

Pull Systems

Stratification

Standardise

Setup Reduction

TPM, 5S

Process Flow

Line Balance

DOE

Hypothesis Testing

Check Sheet

Run Charts

Histograms

Scatter graph

Control Chart

Visual Cntl

Poka-Yoke

Pareto Chart

Interactive Reviews

Control Measures

“ If you have pride in your organisation, you can get your people to do anything.” - Joe Paterno

“ If you have pride in your organisation, you can get your people to do anything.”

- Joe Paterno

Good Luck http://www.linkedin.com/in/anandsubramaniam

Good Luck

http://www.linkedin.com/in/anandsubramaniam