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Yellow belt.pps
- 1. Copyright © 2015 Triumph Institute of Quality Application
Lean Six Sigma Yellow Belt Program
Spreading the Culture of Quality….
Empowering You to Live Your Potential
- 2. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Congratulations
for joining the Lean Six
Sigma journey
Welcome!
- 3. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Training Objectives
Recognize the importance of Quality in the world today
Understand the history of Lean and Six Sigma
Define the terms Lean and Six Sigma
Identify the DMAIC methodology
- 4. Copyright © 2016 TriQA Consulting Pvt. Ltd.
“Lessons are not given, they are taken”
- Unknown Author
Food for Thought
- 6. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Contents
• Quality Concepts
What is Quality?
Why Quality is important?
Cost Impacted by Quality
• Lean Concepts
What is Lean?
Evolution of Lean
Five Principles of Lean
Types of Value
Value Add, Value Enabling and Non-Value Add activities
8 Wastes in Lean
• Six Sigma Concepts
What is Six Sigma?
Six Sigma Methodologies
Evolution of Six Sigma
Six Sigma in Numbers
Six Sigma Team
DMAIC Framework
- 8. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Quality Concepts
• Quality Concepts
What is Quality?
Why Quality is important?
Cost Impacted by Quality
• Lean Concepts
What is Lean?
Evolution of Lean
Five Principles of Lean
Types of Value
Value Add, Value Enabling and Non-Value Add activities
8 Wastes in Lean
• Six Sigma Concepts
What is Six Sigma?
Six Sigma Methodologies
Evolution of Six Sigma
Six Sigma in Numbers
Six Sigma Team
DMAIC Framework
- 9. Copyright © 2016 TriQA Consulting Pvt. Ltd.
What is Quality?
Although there are many ways to define Quality, the most commonly used definition
and the most appropriate in our context is:
Quality is the ability of a Product or Service to meet or exceed
customer’s expectations consistently.
Quality then, is not defined by the producer or service provider, but
by the customer who uses or receives the output.
- 10. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Why Quality is Important?
Below are some of the Quality related problems being faced by organizations today.
Globally, organizations are incurring losses due to lack of quality output, outdated practices,
and broken processes.
- 11. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Cost Impacted by Quality
Perception of Costs impacted by
Quality – (4 % to 5% of Sales)
Reality of Costs
impacted by Quality –
(15% to 25% of Sales)
Organizations can improve the profitability by establishing
Quality at its core !!!
* Source : Juran Institute
- 13. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Lean Concepts
• Quality Concepts
What is Quality?
Why Quality is important?
Cost Impacted by Quality
• Lean Concepts
What is Lean?
Evolution of Lean
Five Principles of Lean
Value Add (VA), Non-Value Add (NVA)
and Value Enabling (VE) activities
8 Deadly Wastes
• Six Sigma Concepts
What is Six Sigma?
Six Sigma Methodologies
Evolution of Six Sigma
Six Sigma in Numbers
Six Sigma Team
DMAIC Framework
- 14. Copyright © 2016 TriQA Consulting Pvt. Ltd.
A tool-based methodology focused on eliminating waste from a process so
that all the activities in a process add value from the customer’s
perspective.
“Lean is a philosophy that shortens the timeline between the customer
order and the shipment by eliminating waste.”
- John Shook
Toyota’s first American manager in Japan
What is Lean?
- 15. Copyright © 2016 TriQA Consulting Pvt. Ltd.
•Productivity
•Quality
•On-time delivery
•Capacity
•Profit
•Cost
•Defects
•Lead time
•Space
•Waste
Decreases
Lean Benefits
- 16. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Evolution of Lean
TOYOTA
James P Womack published two books “The
machine that changed the world” in early
90s and “Lean Thinking” in 1997
- 17. Copyright © 2016 TriQA Consulting Pvt. Ltd.
5 Principles of Lean
Specify
Value
Map the
Value
Stream
Establish
Flow
Implement
Pull
Strive for
Perfection
Lean
Principles
1. Specify Value
If a customer is willing to pay for product or service,
the activity performed transforms the product or
service and if the activity is done first correct, we
say that the product or service brings value to
customer. Value is always defined by the customer
2. Map the Value Stream
Map all the steps that are
conducted in sequence to
bring the product or service
to the customer. A Value
stream map thus created will
help us to look at the
process from a customer's
lens
3. Establish Flow
Ensure a continuous flow product of
services from end to end throughout
the process. Absence of flow will
lead to wait-time, hand offs and
delays. When flow is established,
movement of the product or service
becomes seamless
4. Implement Pull
Nothing is done by the process
unless a need is signaled by the
customer. Customer demand pulls
the product or service through the
value stream
5. Strive for Perfection
Elimination of all wastes from
the process so that activities
create value for the customer.
The journey for perfection
starts with breakthrough and
continuous improvement.
Striving for Perfection is a
relentless pursuit.
- 18. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Value Add, Non-Value Add and Value Enabling Activities
Start
Does it
transform good
or service?
Ascertain
the step to be
Analyzed
Is the
Customer
Willing to
Pay?
Is it
done Right the
first time?
Is it a Business
Requirement?
Y
Y
Y
Value Add
Value Enabling
Non-Value Add
Stop
Y
N
N
N
N
- 19. Copyright © 2016 TriQA Consulting Pvt. Ltd.
8 Deadly Wastes(DOWNTIME)
Inventory
Supplies or raw materials above the
minimum to perform the activities
Leads to over stocking of materials
Extra Processing
Extra Processing anything that does not
add value
Extra Sign Offs, Reports that contains
more information than customer requires
Transportation
Unnecessary movement of material or
information
Leads to extra steps in the process
Motion
Unnecessary movement of people or
equipment at the workplace
Leads to extra steps, data entry and
search
Defects
Change, repair or correction in a product
after it has been made
Leads to re-work in the process
Wait time
Waiting for material, people, equipment,
information and others
Adds to the overall time to provide the
product or service
Non-Utilized Human Intellect
Failure to use the time and talent of the
people
Leads to under utilized resources in the
system
Overproduction
Producing more than or faster than the
customer requires
Leads to excessive Work in Progress or
finished product
8 Deadly Wastes
- 20. Copyright © 2016 TriQA Consulting Pvt. Ltd.
• 5s
• Visual control
• Standardized work
• Value stream mapping
• Pull Production
• Mistake proofing
• Just-in-Time
• Jidoka
Lean Tools
- 21. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Six Sigma Concepts
• Quality Concepts
What is Quality?
Why Quality is important?
Cost Impacted by Quality
• Lean Concepts
What is Lean?
Evolution of Lean
Five Principles of Lean
Types of Value
Value Add, Value Enabling and Non-Value Add activities
8 Wastes in Lean
• Six Sigma Concepts
What is Six Sigma?
Six Sigma Methodologies
Evolution of Six Sigma
Six Sigma in Numbers
Six Sigma Team
DMAIC Framework
- 22. Copyright © 2016 TriQA Consulting Pvt. Ltd.
What is Sigma (σ)?
Greek Letter
Sigma is the 18th Letter of
the Greek alphabet
Standard Deviation
Symbol for Standard
Deviation
It is a measure of
Variation
Process Capability
A Measure of Process
Capability
A Statistical Measure of a
process’s ability to meet
customer requirements
- 23. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Six Sigma…
All work are processes that can be defined, measured, analyzed, improved and controlled
(DMAIC). Process requires inputs and produce outputs. Statistically expressed as y=f(x)
All qualitative and quantitative techniques used by six sigma experts to drive process
improvements. For ex: SPC, FMEA, Process Mapping etc.
Rigorous DMAIC approach which defines the steps a Six Sigma practitioner is expected to
follow, starting with problem identification and ending with implementing sustainable
solutions
It means 3.4 defects per million opportunities (DPMO)
PHILOSOPHY
METHODOLOGY
SET OF TOOLS
METRICS
- 24. Copyright © 2016 TriQA Consulting Pvt. Ltd.
• Six Sigma has broadly two methodologies- DMAIC and DMADV
• DMAIC refers to a data-driven quality strategy for improving processes
• DMAIC is an acronym for five interconnected phases: Define, Measure,
Analyze, Improve, and Control.
Six Sigma - Methodologies
• DMADV is a data-driven quality strategy for designing products and
processes
• It is Used for new product/service introduction and hence also called DFSS
(Design for Six Sigma)
• DMADV consists of five interconnected phases: Define, Measure, Analyze,
Design, and Verify.
- 25. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Six Sigma – DMAIC Vs DMADV
Six Sigma involves two methodologies, DMAIC and DMADV. The following
flow diagram helps in selecting the right approach.
Measure
Analyze
Design
Verify
Measure
Analyze
Improve
Control
Define
Does a
process
exist?
Yes
YesNo
No
DMADV/
DFSS
DMAIC
DMADV: Define Measure Analyze Define Verify
DFSS: Design For Six Sigma
DMAIC : Define Measure Analyze Improve Control
Is
incremental
improvement
Enough?
- 26. Copyright © 2016 TriQA Consulting Pvt. Ltd.
• Carl Frederick Gauss (1777-1855) introduced the concept of the normal
curve
• In the late 1970's, Dr. Mikel Harry, a senior staff engineer at Motorola's
Government Electronics Group (GEG), experimented with problem solving
through statistical analysis. Using this approach, GEG's products were
being designed and produced at a faster rate and at a cheaper price
• Subsequently, Dr. Harry began to formulate a method for applying six
sigma throughout Motorola.
Six Sigma Evolution
- 27. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Six Sigma Roles
Green Belt
Learn LSS Methodology
and Tools
Apply LSS to Projects in
current Job scope
Work on their own with
some mentoring
Black Belt
Lead Multiple LSS
Projects
Apply LSS to individual
Projects working
independently
Mentor Green Belts and
others
Cultural Change agent
for LSS
Master Black Belt
Trains others in LSS
Identify High Impact
improvement areas and
initiatives
Ensure LSS rigor in the
organization (Project
Reviews)
Mentor Black Belts and
Green Belts
Cultural Change agent
for LSS
Sponsors : Has a stake and is interested in the outcome of the project. One of the people
to sign-off the project. Usually Business Unit Head, Head of the Department etc.
Champions: Has a stake in the project and removes the roadblocks for the Project
Team Members: Members of the improvement project team. Heavily involved in each
step of the project
- 28. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Six Sigma – In Numbers
Sigma
Level
Defects / Errors % Good
2 308,537 70%
3 66,807 93%
4 6,210 99.4%
5 233 99.98%
6 3.4 99.99966%
As the number of defects in a process decreases, the % Good
in that process and the sigma level of that process increases.
- 29. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Six Sigma - DMAIC
1
2
3
Define
Measure
Analyze
Improve
Identify a manageable and
customer focused area for
improvement
Understand the measures
around the problem, the
measurement system and
create a baseline
Sustain the results
Develop, Test and Implement the
solutions that address the root
cause
3
4
5 Control
Identify root causes of defects
and validate them with data
VOC to CTQ
Project Charter
SIPOC or COPIS
Project Y
Performance Standard
Data Collection Plan
MSA and Collection of Data
Process Capability
Improvement Goal
Hypothesis Testing
Prioritized Xs
Identify & Pilot Solution
Refine Solution
FMEA and Poka Yoke
MSA, Process Capability
Statistical Process Control
Control Plan & Documentation
StepsPhases Tools Used
Go to the next slide
- 30. Copyright © 2016 TriQA Consulting Pvt. Ltd.
Congratulations
for completing TriQA’s
Yellow belt course
Thank You !!!
Go to The Next Slide to Print Your Yellow Belt Course Completion Certificate
and View the Six Sigma Journey for You.
- 31. Copyright © 2016 TriQA Consulting Pvt. Ltd.
• Lean Six Sigma Yellow Belt – Completed
Way Forward
• Lean Six Sigma Green Belt
• Lean Six Sigma Black Belt
• Lean Six Sigma Master Black Belt
All the Lean Six Sigma programs are offered by TriQA Consulting Pvt.
Ltd. Please visit our website www.triqa.org for details and training
schedule of programs.
Click the Exit button to view and print your Lean Six Sigma Yellow
Belt certificate
The Lean Six Sigma Journey…..