LEAN Six Sigma - An Introduction


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Lean Six Sigma - An Introduction

This PDF document helps us to understand the below.

1] What is Lean Six Sigma
2] Why Lean Six Sigma
3] Road Map to Certification -
- How ?
- When ?
4] Value of Six Sigma
5] Summary

Published in: Business, Technology

LEAN Six Sigma - An Introduction

  1. 1. o What is Lean Six Sigma… o Why Lean Six Sigma… o How we do… o When to doJourney Towards Operational Excellence….. 1
  2. 2. Lean Six Sigma is a Business Management Strategy … Seeks to identify and remove the causes of defects and errors Uses a set of management methods, including statisticalmethods Creates a high performing culture within the organizationAims To Deliver Breakthrough Performance In Business Or Operational Measures Like Customer Satisfaction Rating Score Cost of executing a business process transaction Billing and Cash Collection lead time Yield (Productivity) of service operations or production “When you are finished changing, youre finished.” Benjamin Franklin 2
  3. 3. ...Features that clearly distinguish Lean Six Sigma from other quality methodology Six Sigma Lean is a Motorola has reported over rigorous, data-driven, result US$17 oriented approach to billion in process improvement. savings from It helps in improving Six Sigma as of 2006 quality, efficiency & speed in every aspect of business 1) Ability to distinguish the problems and symptoms 2) Structured approach to problem solving 3) Root cause analysis for permanent fixes 4) Leverage the tools, techniques and best practices for data analysis and solution 1) Able to achieve growth through increased productivity 2) Achieve great customer satisfaction 3) Improves employee engagement & satisfaction 4) Creates an overall high performing culture within the organization 5) Gives a competitive edge in the market place “It is not enough to do your best; you must know what to do, and then do your best “ - DemingCompany Confidential 3
  4. 4. Defining Road mapInstitutionalizing Yellow Belt Training & Lean Six Sigma Monitor Certification Culture Train Black Belt Organizational Training & Consult Framework Certification Green Belt Training & Certification Our objective is to create value proposition & business outcomes through six sigma consulting… 4
  5. 5. 1 •Define Goals & objectives  Lean/Six Sigma •Discussions on current issues Program Rollout Define •Why Six Sigma ( benefits)  Employee Training plan Lean Six Sigma •Training & Certification criteria; Role definition  Six Sigma/Lean Strategy •Benefits Realization & Review Mechanism Training Calendar •Establish communication plan and channels for rollout  Employees/Stakeholder notification2 Lean, Six-sigma •Six Sigma Awareness & LEAN  Lean/Six Sigma awareness across the Yellow Belt •Training duration - 1 day; 7 hours training & 1 hour evaluation board  Yellow Belt Certification Basic Training •Recommendation - 2 weeks/month; 5 Days/Week : 25 for ~500 employees in & Certification Participants/Session) India3 •Define Annual Savings Target •KRAs to employees for Lean/Six Sigma  Goal setting Organizational •Metrics capturing & Reporting Framework •Core Six Sigma team identification to steer the  Employee initiative throughout the organization Communication •Define framework for Quality projects identification A journey of a thousand miles begins with a single step 5
  6. 6. 4 Lean, Six-sigma • Green Belt Training  Green Belt Training Green Belt • Training Duration - 4 days (Weekdays, or weekdays Participant Certification + weekends by continuous)  Completed one Six Training & • Recommendation - 2 trainings/month ; Sigma Project Certification 15 Participants/Session; ~115 participants  Green Belt Certification5  Black Belt Participation Lean, Six-sigma • Black Belt Training Certification Black Belt • Training Duration - 8 days (Wednesday to Saturday -  Completed One Six Sigma 2 weeks) Project Training & • Recommendation - 1 training/month ; 10  Mentored two Six Sigma Certification Participants/Session; ~50 participants Projects  Black Belt Certification6 • Yearly Target Plan for Lean Six Sigma Institutionalizing • Lean Principles well deployed – 5S, Value Stream  Culture change Mapping, Kaizen Lean Six Sigma • Lean Six Sigma mentor and champions should be  Company-wide Culture Implementation Plan easily available during this phase to encourage and guide new teams A journey of a thousand miles begins with a single step 6
  7. 7. Organizational Frame work Green Belt Certification Yellow Belt Certification Yellow Belt CertificationDefine Lean Six Sigma Yellow Belt Certification Strategy Green Belt Certification Green Belt Certification Green Belt CertificationGreen Belt Certification Green Belt Certification 5S, Kaizen, Value Black Belt Certification Stream mapping 5S, Kaizen, ValueGreen Belt Certification Green Belt Certification Stream mapping Black Belt Certification Black Belt Certification Black Belt CertificationBlack Belt Certification 5S, Kaizen, Value 5S, Kaizen, Value 5S, Kaizen, Value Stream mapping Stream mapping 5S, Kaizen, Value Stream mapping Stream mapping A journey of a Thousand miles begins with a single step 7
  8. 8. Target Audience Type Pre-Requisite Training Approach Certification Criteria (Minimum) Instructor led Class All employees Room Training 1) Attending the YB TrainingYellow Belt None including support 2) Scoring 75% + in the evaluation test function Long term - Web Based Training Team Leaders, Group 1) Attending the GB Training Leaders & Project 2) Scoring 75% + in the GB evaluation Yellow Belt Managers Instructor led ClassGreen Belt test Certified Room Training 3) 1 Green Belt project completion with (25% of the total annual saving of $5,000.00 or above work force) 1) Attending the BB Training 2) Scoring 75%+ in the BB evaluation Project Managers test Green Belt Instructor led ClassBlack Belt 3) 2 GB Projects completion with total Certified (10% of the total Room Training annual savings of $10,000 or above work force) 4) Mentoring of 2 GB projects along with their certification A Journey of a Thousand miles begins with a single step 8
  9. 9. Designing Six Sigma Framework•Designing the Six Sigma Strategy and Road map aligned to Organization’s goals & objectives•Goal setting for Six Sigma Strategy•Lean Six Sigma Initiative branding•Mechanism to Track & Report Benefits RealizationTraining & Certification•Designing the Training Calendar for Lean Six Sigma as per the Organization’s HR/Training guidelines•Certification criteria that is aligned to Organization’s Six Sigma Strategy•Evaluation Question Paper to include both theoretical and Scenario based questionsConsultation & Mentoring•Conduct work shops, Brain storming sessions to identify opportunities for Lean & Six Sigma projects also best practice sharing•Help the team with the DMAIC/DMADV documentation and tollgate approvals•Mentoring 10 Green Belt Projects•Tracking and Reporting Benefits With Lean Six Sigma… Only results counts… 9
  10. 10. Focus on Preliminary requirements while embarking on Lean Six Sigma Imperative to adopt the phase wise roadmap for a systematic approach Need to promote it as a way of life from now onwardsOther early adopters of Six Sigma who achieved great success include HoneywellInternational and General Electric.By the late 1990s, about two-thirds of the Fortune 500 organizations had begun SixSigma initiatives with the aim of reducing costs and improving quality. Let’s Begin The Journey Towards Operational Excellence… 10