Zero Defects Through Lean Six Sigma

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Zero Defects Through Lean Six Sigma

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Zero Defects Through Lean Six Sigma

  1. 1. ZERO DEFECTS THROUGH LEAN-SIGMA The necessary skill-set to achieve ZERO DEFECTS in fast track with Advanced Manufacturing Consultancy Sdn. Bhd.
  2. 2. Contents <ul><li>Why Zero Defects </li></ul><ul><li>Brief Background of Lean-Sigma </li></ul><ul><li>The AMC Lean-Sigma program </li></ul>
  3. 3. Why Zero Defects <ul><li>Philip Crosby popularized the concept of Zero Defects and he made it clear that there is something called “COST OF POOR QUALITY” </li></ul><ul><li>Defects COST MONEY! </li></ul><ul><li>Today’s business scenario makes it imperative that you provide Excellent Quality to customers or lose their business </li></ul>Philip Crosby 1926-2001 <ul><li>Most companies implement ‘Zero Defects’ initiatives but struggle with results due to: </li></ul><ul><ul><li>Lack of skills and experience in employees to create a Zero Defect environment </li></ul></ul><ul><ul><li>Lack of motivation and drive to do it </li></ul></ul><ul><li>RESULTS ARE SLOW! </li></ul>CAN YOU WAIT YEARS TO ACHIEVE ZERO DEFECTS?
  4. 4. FAST TRACK APPROACH TO ACHIEVE YOUR TARGET <ul><li>Allow us to develop the skills and motivation in your employees using </li></ul><ul><li>LEAN-SIGMA methodologies to achieve </li></ul><ul><li>ZERO DEFECTS . </li></ul><ul><li>Let them achieve “bulls eye” results always with these proven methodologies </li></ul>
  5. 5. Brief Background <ul><li>Many world class companies have achieved great savings and improvement through two of the most effective methodologies of this time-Lean and Six Sigma </li></ul><ul><li>However, despite spending lots of money and resources these initiatives have left them with certain drawbacks: </li></ul><ul><ul><li>Six Sigma does not address process speed and lacks improvement in Lead Times </li></ul></ul><ul><ul><li>Six Sigma practitioners focus only on improving variations on specific areas/processes with little impact to overall business </li></ul></ul><ul><ul><li>Companies implementing Lean aren’t effective in deploying it across the corporation at a rapid speed </li></ul></ul><ul><ul><li>Lean Tools lack a robust analytical process of problem solving to make change last </li></ul></ul><ul><li>In short: </li></ul><ul><ul><li>LEAN CANNOT BRING PROCESS UNDER STATISTICAL CONTROL </li></ul></ul><ul><ul><li>SIX SIGMA CANNOT IMPROVE LEAD TIME A GREAT DEAL OR REDUCE CAPITAL INVESTMENT </li></ul></ul>
  6. 6. Brief Background <ul><li>The solution to this drawback is an approach where Lean & Six Sigma are merged as a more powerful improvement methodology called LEAN-SIGMA </li></ul><ul><li>The LEAN-SIGMA methods prove to wipeout the weaknesses the tools applied in isolation </li></ul><ul><li>The LEAN-SIGMA methods are already applied widely and successfully by big companies such as: </li></ul><ul><ul><li>GE </li></ul></ul><ul><ul><li>Honeywell </li></ul></ul><ul><ul><li>NCR </li></ul></ul><ul><ul><li>ITT Industries </li></ul></ul><ul><ul><li>Rockwell </li></ul></ul><ul><ul><li>Raytheon </li></ul></ul><ul><ul><li>Caterpillar and many others </li></ul></ul>
  7. 7. BREAKTHROUGH APPROACH WITH LEAN-SIGMA TOOLS AMC has developed the “Zero Defects Through Lean-Sigma” program by tapping on the most powerful tools of Six Sigma & Lean with a special focus on Quality Improvement The program is developed with SPEED and RESULTS in mind and with a clarity and simplicity where the tools can be taught to even persons without any technical or engineering background. The effectiveness of the tools are guaranteed
  8. 8. THE PROGRAM DETAILS ZERO DEFECTS THROUGH LEAN-SIGMA
  9. 9. Objective of the Program <ul><li>The program is designed to provide hands-on knowledge and guidance to participants to use the Six Sigma DMAIC (Define, Measure, Analyze, Improve & Control) problem solving process to improve Quality and eliminate/reduce defects </li></ul><ul><li>The program uses Proven Six Sigma statistical tools and selected Lean Tools tailor made to improve process robustness and Quality within a very short period of time </li></ul><ul><li>The program is delivered in a pragmatic and easy manner so that even non-technical participants can grasp and use the methodology immediately </li></ul><ul><li>It is targeted to equip those working on Zero Defect projects in an organization with the right Lean-Sigma competency </li></ul>
  10. 10. The Program Outline <ul><li>Wave 1 (2 DAYS) </li></ul><ul><li>Background of Quality Excellence and its importance in today’s business scenario </li></ul><ul><li>Overview of Achieving Zero Defects Through Lean-Sigma: Class Room Simulation </li></ul><ul><li>Value Stream Mapping & Red Flagging for Quality improvement </li></ul><ul><li>Measuring Cost of Poor Quality </li></ul><ul><li>Project Management & Motivation for Zero Defects </li></ul>
  11. 11. The Program Outline <ul><li>Wave 2 (3 DAYS) </li></ul><ul><li>Solving Problems using the DMAIC process </li></ul><ul><li>Define Phase Tools: Affinity Diagrams, Interrelation Diagram, QFD & SIPOC, 5-Why </li></ul><ul><li>Measure Phase Tools: Pareto, Gage R & R, Histogram & Process Capability </li></ul><ul><li>Analyze Phase Tools: C&E, RCA, Scatter charts, multivari charts </li></ul>
  12. 12. The Program Outline <ul><li>Wave 3 (4 DAYS) </li></ul><ul><li>Improve Phase Tools: DOE, Tree Diagram, FMEA, </li></ul><ul><li>Improve Phase Lean Tools: Robust Setups, TPM Equipment Improvement, Visual Systems & Standardized Work for Quality, 2S for Quality </li></ul><ul><li>Wave 4 (3 DAYS) </li></ul><ul><li>Control Phase Tools: Process Control, Pokayoke, Pareto, Control Chart </li></ul><ul><li>Case Study </li></ul>
  13. 13. The Program Delivery Method <ul><li>The program is delivered in a Learn-Do-Mentor approach which is unique to AMC </li></ul><ul><li>Each participant will be required to one practical Quality Improvement or Defect Elimination project using the tools taught through the course of the training </li></ul><ul><li>The Wave training are delivered with a 2 – 3 weeks interval to allow participants time and opportunity to use the tools taught on their practical project </li></ul><ul><li>AMC consultants will provide 1 day of project mentoring session between each Wave where each participant will spend 1 hour with the consultant </li></ul>
  14. 14. Summary of Program PROGRAM ACTIVITY # DAYS Wave 1 2 Wave 2 3 Projects Mentoring 1 Wave 3 4 Projects Mentoring 1 Wave 4 3 Projects mentoring 1 Total 15
  15. 15. WHAT NEXT? <ul><li>Allow us to come in and give a full presentation on this program which can bring quantum benefits to your company within a short period of time </li></ul><ul><li>YOU CAN SAVE MONEY THROUGH QUALITY IMPROVEMENT </li></ul>CONTACT US: Lawrence +6016-566 2810 Fax:+605-526 1090 Email: [email_address] or [email_address]

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