Lean Six Sigma




   Department of Defense
      Lean Six Sigma

            -Introduction-




                         ...
Learning Objectives
      Lean Six Sigma


 Class Introductions
 Review Training Materials and Software
 Establish Code...
Class Introductions
        Lean Six Sigma


   Name
   Organization and location
   Years experience with DoD
   Hobb...
Training Materials and Software
          Lean Six Sigma


 DEPMS: DoD Enterprise        MINITAB:
Performance Management...
Code of Conduct
          Lean Six Sigma


   Everyone participates with equal voice
   High level of participation need...
Instructor Expectations
            Lean Six Sigma


 Instructors’ expectations are that you will:
      Come to class p...
Classroom Logistics
          Lean Six Sigma


 Class Hours
 Safety
       Fire exits and where to congregate
       T...
Our Learning Environment
       Lean Six Sigma


   Prework
   Classroom concept lecture / discussion
   Classroom appl...
How Do We Learn?
   Lean Six Sigma


Retention Rate   Teaching Techniques          Characteristics
                       ...
Class Baseline
       Lean Six Sigma



 Statistical Baseline - Our personal knowledge:
      1 – I have never used stat...
Course Schedule
                     Lean Six Sigma


    Monday                     Tuesday               Wednesday      ...
What We Have Covered
       Lean Six Sigma


 Introduction to class instructors and participants
 Necessary software and...
Lean Six Sigma




   Department of Defense
      Lean Six Sigma

                 -Overview-




                        ...
Learning Objectives
         Lean Six Sigma


 At the end of this training you will:
      Be aware of DoD policy regard...
Foundation to Lean 6 Sigma
           Lean Six Sigma



Definitions of Insanity:

Doing the same thing over and over
and e...
Policy Overview
        Lean Six Sigma


 Process Improvement Guidelines
 Principles and Tools
 OSD Performance Improve...
Performance Improvement Cycle
        Lean Six Sigma

                                      PLANNING
                     ...
Strategic Alignment
       Lean Six Sigma



 The Define Tollgate requires a linkage to how this
  project aligns to the ...
Value Streams & DoD Enterprise
        Lean Six Sigma




                                                                ...
DMAIC Model
Lean Six Sigma




                  20       UNCLASSIFIED
DMAIC Linkages
                        Lean Six Sigma

                                                                   ...
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  1. 1. Lean Six Sigma Department of Defense Lean Six Sigma -Introduction- UNCLASSIFIED
  2. 2. Learning Objectives Lean Six Sigma  Class Introductions  Review Training Materials and Software  Establish Code of Conduct, Instructor Expectations, and Logistics  Understand the Adult Learning Environment  Use data to establish a Lean Six Sigma baseline for the class  Review the Lean Six Sigma improvement process and topics to be covered in class 2 UNCLASSIFIED
  3. 3. Class Introductions Lean Six Sigma  Name  Organization and location  Years experience with DoD  Hobby/interest  Project problem statement  Expectations 3 UNCLASSIFIED
  4. 4. Training Materials and Software Lean Six Sigma  DEPMS: DoD Enterprise  MINITAB: Performance Management System  Data Analysis  Document Projects  Requires License  Research Replicates  www.minitab.com  Gate Approvals  DMAIC Templates  EXCEL:  Other tools  Data Analysis https://psxl.psteering.com/DEPMS  Requires Data Analysis add-in  Choose Office-> EXCEL options; Select Class Materials: Add-ins; Select Analysis ToolPak; click Go. Select Analysis ToolPak, click OK.  Laptop with MINITAB & EXCEL  Access to DEPMS  Simulation:  Print-out of Class Slides  Role Instructions  Web-link to:  Supply Store  Student Participant Guide  Document Repository  Minitab and EXCEL PEs  DEPMS training (Prework)  Glossary 4 UNCLASSIFIED
  5. 5. Code of Conduct Lean Six Sigma  Everyone participates with equal voice  High level of participation needed for success  Single discussions (respect the speaker)  All ideas welcome  Confidentiality - what happens here stays here!  Respect our time together  Return from breaks/lunch on time  Use “parking lot” and “ELMO” to manage discussions  Handle outside business on breaks  Blackberries / Phones / electronics off or on vibrate  Function as a team – everyone facilitates at least one exercise  Have fun! 5 UNCLASSIFIED
  6. 6. Instructor Expectations Lean Six Sigma  Instructors’ expectations are that you will:  Come to class prepared  Adhere to the Code of Conduct  Ask questions and participate  Practice team leadership and facilitation skills during class  Teach-backs  Simulation  Class Exercises  Keep an open mind  Have fun! 6 UNCLASSIFIED
  7. 7. Classroom Logistics Lean Six Sigma  Class Hours  Safety  Fire exits and where to congregate  Trips and other hazards  Restroom facilities  Breaks  Lunch accommodations  Others? 7 UNCLASSIFIED
  8. 8. Our Learning Environment Lean Six Sigma  Prework  Classroom concept lecture / discussion  Classroom application – Instructor led  Classroom application – Team lead  Classroom team teach-back  Homework assignments  Homework debrief 8 UNCLASSIFIED
  9. 9. How Do We Learn? Lean Six Sigma Retention Rate Teaching Techniques Characteristics Time Pressured 5% Presentation Content Focused Spray and Pray 10% Reading 20% Audio-Visual 30% Demonstration 50% Discussion 75% Practice with Feedback Learner Focused Interactive 80% Teach Others/Immediate Use Time-Consuming 9 UNCLASSIFIED
  10. 10. Class Baseline Lean Six Sigma  Statistical Baseline - Our personal knowledge:  1 – I have never used statistical methods  3 – I use some data occasionally  5 – I use data frequently  7 – I almost always use data and know what to do with it  9 – I should be teaching this stuff  Lean Baseline – Our personal knowledge:  1 – I have never used lean tools/techniques  3 – I use lean tools sometimes  5 – I use lean tools a lot  7 – I always use lean, regardless of the process/environment  9 – I should be teaching this stuff 10 UNCLASSIFIED
  11. 11. Course Schedule Lean Six Sigma Monday Tuesday Wednesday Thursday Friday 25 Nov 1 – Introduction Teachbacks Teachbacks Teachbacks Review 6 – Measure 6 – Measure 9 - Round 2 13 – OSD Final 2 –Performance Phase 3 Dec Simulation Exam Improvement 1 Dec Overview 10 – Improve 7– Analyze Phase Cont 14 - Project Phase 3 – Management 10 Dec Presentations Team 17 Dec Change 8– Improve 11– Control Project Phase Phase *Saturday 8 Dec 15 – DA Exam 4 – Define Phase 12 – Class Prep Review 18 Dec 5 – Round 1 Simulation 16 – DA Final 15 Dec Exam 28 Nov * Optional: Required for the award of the ARMY LSS ASI 11 UNCLASSIFIED
  12. 12. What We Have Covered Lean Six Sigma  Introduction to class instructors and participants  Necessary software and training materials  Code of Conduct, Instructor Expectations, and Class Logistics  An understanding of the learning process, learning environment, and LSS learning focus  Appreciation of our baseline familiarity and comfort level working with statistical data and Lean  Overview of the Lean Six Sigma Course Schedule 12 UNCLASSIFIED
  13. 13. Lean Six Sigma Department of Defense Lean Six Sigma -Overview- UNCLASSIFIED
  14. 14. Learning Objectives Lean Six Sigma  At the end of this training you will:  Be aware of DoD policy regarding Lean Six Sigma deployment  Be aware that Performance Improvement efforts should link to enterprise value streams, linking mission and vision  Appreciate that different deployment models that exist  Appreciate differences between various project implementation strategies and when to use each model  Be aware of the history of Lean, Six Sigma and Theory of Constraints  Be aware of OSD’s LSS certification requirements 14 UNCLASSIFIED
  15. 15. Foundation to Lean 6 Sigma Lean Six Sigma Definitions of Insanity: Doing the same thing over and over and expecting a different outcome! AND Using the same logic to get out of the trouble that got you there in the first place! -Albert Einstein 15 UNCLASSIFIED
  16. 16. Policy Overview Lean Six Sigma  Process Improvement Guidelines  Principles and Tools  OSD Performance Improvement / LSS Charter  DepSecDef memo of 11 May 2006  DepSecDef memo of 30 April 2007  DoDD 5010.42 15 May 2008  DoDI 5010.43 17 Jul 2009  Performance Excellence… A Lean Six Sigma World- Class Methodology  Where to Start…Voice of the Customer 16 UNCLASSIFIED
  17. 17. Performance Improvement Cycle Lean Six Sigma PLANNING 1. Develop Vision, Mission & Strategy • Who am I? • Where am I going? • What do I need to get done? B. Implement Operational Plan 2. Conduct a Value RE-ENTRY (Meet my Stream Analysis commitment) • How will I get there? A. C. Create & Refine Monitor Progress Operational Plan IMPLEMENTATION (How am I (What’s my doing?) plan?) D. Focus D. PIPI on (How Focus on CPI can I do it again? (How can can I it again? How I do do it How can I do it better? 4. Align & better? How can I How can I kill it?) 3. Develop kill it? Deploy Goals Structure & Behavior • How will I get • What will I need? people to do it? 17 UNCLASSIFIED
  18. 18. Strategic Alignment Lean Six Sigma  The Define Tollgate requires a linkage to how this project aligns to the organizational strategy.  Include an organizational metric/metrics for which your project will help improve  Refer to your organization’s Strategic Plan and/or other referenced documents Required Define Phase Deliverable 18 UNCLASSIFIED
  19. 19. Value Streams & DoD Enterprise Lean Six Sigma g in et g re in g on u n d ct t ce t n u ti en or & en u B la ta op & an el tr sp e m m P , g an ag n el n as n re on in n ev ig te Tr tor fr so n cu al es si n In n er g ai is S D ro la Le M M P IT P D P Human Resource Management W A Weapon System Lifecycle Management R F I Real Property & Installation Lifecycle Management G H T Materiel Supply & Service Management E R Financial Management S Value Streams (red and yellow) 19 UNCLASSIFIED
  20. 20. DMAIC Model Lean Six Sigma 20 UNCLASSIFIED
  21. 21. DMAIC Linkages Lean Six Sigma Gage R&R Critical Suppliers Inputs Process Outputs Customers Customer Requirements CTQ Input, Process & Output Defects Fishbone - Potential X’s & Modes Indicators Process People Measurement Operational Step 3 Step 4 Definitions and Data X4 X2 Indicators Rework No Y X3 X5 X1 Yes Step 1 Step 2 Step 5 Step 6 Step 7 Environment Equipment Materials ProcessCapabilityofLength UCL XY MATRIX OCC Improved Process SEV RP ET Proces N D Process Data LSL USL Within Potential Potential Potential Current LSL 599 Overall s Step Failure Failure Causes Controls Control & Target * X-bar USL 601 Sample Mean 600.072 Potential (Within) Capability Cp 0.28 Modes Effects Sample N StDev(W 100 ithin) 1.17308 StDev(Overall) 1.33501 CPL 0.30 CPU 0.26 Cpk 0.26 Step 1 M1 Y X1 LCL Overall Capability Pp 0.25 PPL 0.27 PPU 0.23 Ppk 0.23 Step 2 M2 Y X2 Performance Process Baseline Cpm * Pareto Step 3 M3 Y X3 FMEA 597 598 599 600 601 602 603 ObservedPerformance PPM <LSL 280000.00 Exp. WithinPerform PPM <LSL 180401.78 ance Exp. Overall Perform PPM<LSL 210989.32 ance Step 4 M4 Y X4 Stratification PPM >USL 350000.00 PPM >USL 214448.35 PPM>USL 243487.40 PPM Total 630000.00 PPM Total 394850.13 PPMTotal 454476.72 Step 5 M5 Y X5 Baseline Capability 1 21 UNCLASSIFIED

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