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Six Sigma Lean (SSL)

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SSL - Process Integration, Tools & Techniques

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Six Sigma Lean (SSL)

  1. 1. Six Sigma Lean (SSL) Integration, Tools & Techniques Anand Subramaniam
  2. 2. <ul><li>“ Remember : If you do what you’ve been doing, you’ll get what you’ve been getting.” </li></ul><ul><ul><li>- Source Unknown </li></ul></ul>
  3. 3. Six Sigma Lean (SSL) <ul><li>Lean </li></ul><ul><li>Focus – Flow </li></ul><ul><li>Goal – Reduce waste and increase process speed </li></ul><ul><li>Focus – Bias for action </li></ul><ul><li>Method – Kaizen events, Value Stream Mapping, process balancing, constraint identification, mistake proofing </li></ul><ul><li>Enablers - Lean Speed enables Six Sigma Quality </li></ul><ul><li>Six Sigma </li></ul><ul><li>Focus - Problem </li></ul><ul><li>Goal – Improve performance on Customer CTQs </li></ul><ul><li>Focus – Use DMAIC with TQM tools to eliminate variation </li></ul><ul><li>Method – Management engagement, 100% dedicated as Champions and Black Belts </li></ul><ul><li>Enablers - Six Sigma Quality enables Lean Speed </li></ul>Compliment each other
  4. 4. What is SSL Methodology ? <ul><li>Starts with the “Voice of the Customer” </li></ul><ul><li>Overall Process Improvement </li></ul><ul><li>Waste Reduction </li></ul><ul><li>Cycle time reduction </li></ul><ul><li>Eliminate Process Variation </li></ul><ul><li>Minimise Resources requirements </li></ul><ul><ul><li>From Design, Make, Market - To delivery of a service and / or product to customers </li></ul></ul>
  5. 5. 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
  6. 6. Why Integrate Both? <ul><li>Increases customer satisfaction </li></ul><ul><li>Requires a different system model </li></ul><ul><li>Improves profitability & competitive position </li></ul><ul><li>Requires implementation & sustaining plans </li></ul>
  7. 7. SSL – Problem Solving Approach Stop Stop Stop Tollgate Review Tollgate Review Tollgate Review Tollgate Review Tollgate Review Stop Stop
  8. 8. What is required <ul><li>Get management commitment </li></ul><ul><li>Assess the operation & understand the process using a Value Stream Map (product families & production data) </li></ul><ul><li>Identify lean improvements & Kaizen without automation </li></ul><ul><li>Implement lean improvements using VSM plan </li></ul><ul><li>Identify processes requiring Six Sigma analysis </li></ul><ul><li>Analyse, eliminate, and control variation </li></ul><ul><li>Start the cycle again </li></ul>
  9. 9. SSL – Tools & Techniques DEFINE IMPROVE CONTROL MEASURE ANALYSE SPECIFY VALUE FLOW PERFECTION UNDERSTAND DEMAND LEVEL <ul><li>Voice of the Customer </li></ul><ul><li>Competitive Benchmark </li></ul><ul><li>Project Definition </li></ul><ul><li>Value of Cycle Time </li></ul><ul><li>PIP Management Process </li></ul><ul><li>RACI </li></ul><ul><li>Value Stream Mapping </li></ul><ul><li>LSS Metrics </li></ul><ul><li>Multi-Voting Techniques </li></ul><ul><li>Pareto Charts </li></ul><ul><li>C&E/Fishbone Diagrams </li></ul><ul><li>FMEA </li></ul><ul><li>Check Sheet </li></ul><ul><li>Run Charts </li></ul><ul><li>Control Chart </li></ul><ul><li>Cp & Cpk </li></ul><ul><li>Complexity analysis </li></ul><ul><li>Multi-Vari </li></ul><ul><li>Box Plots </li></ul><ul><li>Interaction Plots </li></ul><ul><li>Regression </li></ul><ul><li>ANOVA </li></ul><ul><li>C&E Matrices </li></ul><ul><li>FMEA </li></ul><ul><li>Brainstorm </li></ul><ul><li>Affinity </li></ul><ul><li>Benchmark </li></ul><ul><li>Kaizen </li></ul><ul><li>Pull Systems </li></ul><ul><li>Stratification </li></ul><ul><li>Standardise </li></ul><ul><li>Setup Reduction </li></ul><ul><li>TPM, 5S </li></ul><ul><li>Process Flow </li></ul><ul><li>Line Balance </li></ul><ul><li>DOE </li></ul><ul><li>Hypothesis Testing </li></ul><ul><li>Check Sheet </li></ul><ul><li>Run Charts </li></ul><ul><li>Histograms </li></ul><ul><li>Scatter graph </li></ul><ul><li>Control Chart </li></ul><ul><li>Visual Cntl </li></ul><ul><li>Poka-Yoke </li></ul><ul><li>Pareto Chart </li></ul><ul><li>Interactive Reviews </li></ul><ul><li>Control Measures </li></ul>
  10. 10. <ul><li>“ If you have pride in your organisation, you can get your people to do anything.” </li></ul><ul><ul><li>- Joe Paterno </li></ul></ul>
  11. 11. <ul><li>Good Luck </li></ul><ul><li>http://www.linkedin.com/in/anandsubramaniam </li></ul>

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