Lean Six Sigma is a combination of Lean methodology for waste reduction and process improvement with Six Sigma methodology for variability reduction and defect prevention. The presentation provides an overview of Lean Six Sigma, including comparing Lean and Six Sigma approaches, defining value-added activities, and outlining the DMAIC process in Six Sigma and principles of Lean such as identifying the seven wastes. Next steps proposed include identifying Lean Six Sigma projects, documenting current processes, and building a roadmap with milestones.
I've been asked to put together a basic (and therefore relatively quick) introduction to Lean Six Sigma & DMAIC. While it’s not yet finished, I thought I would put it out there for people to comment on. Since the presentation is supposed to be training material there’s more text on the slides than I would prefer, but there are a few exercises and games to get the trainees involved.
I've put the PowerPoint version on my blog:
http://alesandrab.wordpress.com/2013/06/07/introduction-to-lean-six-sigma-dmaic/
DMAIC is a methodology for improving existing processes. DMAIC stands for Define, Measure, Analyze, Improve, and Control.
https://goleansixsigma.com/lean-six-sigma-step-by-step/
Lean six sigma explained: Beginners trainingQualsys Ltd
A free online introduction to Lean six sigma principles.
Includes lean six sigma tools, philosophy, disciplines, history overview of lean six sigma, applying DMAIC for complex decision making, using Qualsys EQMS software for Lean Six Sigma.
I've been asked to put together a basic (and therefore relatively quick) introduction to Lean Six Sigma & DMAIC. While it’s not yet finished, I thought I would put it out there for people to comment on. Since the presentation is supposed to be training material there’s more text on the slides than I would prefer, but there are a few exercises and games to get the trainees involved.
I've put the PowerPoint version on my blog:
http://alesandrab.wordpress.com/2013/06/07/introduction-to-lean-six-sigma-dmaic/
DMAIC is a methodology for improving existing processes. DMAIC stands for Define, Measure, Analyze, Improve, and Control.
https://goleansixsigma.com/lean-six-sigma-step-by-step/
Lean six sigma explained: Beginners trainingQualsys Ltd
A free online introduction to Lean six sigma principles.
Includes lean six sigma tools, philosophy, disciplines, history overview of lean six sigma, applying DMAIC for complex decision making, using Qualsys EQMS software for Lean Six Sigma.
Lean Six Sigma is a methodology that combines the methods and concepts of Lean Manufacturing with those of Six Sigma. This presentation is a basic overview of the implementation of lean six sigma. Presentation by EMS Consulting Group, Inc. www.emsstrategies.com
Lean Six Sigma is a process improvement methodology that relies on a collaborative team effort to improve performance by systematically removing waste, combining Lean and Six Sigma to eliminate the eight kinds of waste
Lean Six Sigma projects comprise aspects of Lean's waste elimination and the Six Sigma focus on reducing defects
Basic understanding of lean six sigma approach for improvementViral Jain
Before we start working on a project for process improvement.
It is very important to create awareness.
I made this presentation to provide basic understanding of Lean and six sigma.
Usually audience used to be SME, process owner and Higher management people.
After this training ,audience gets a roadmap/ strategy for improvement and how I will help them to improve.
I take their inputs after training and than we start with VOC, VOB and identification of problems and this is how I prefer to start.
During this 1-hour webinar recording, you will receive a basic introduction to what Lean Six Sigma is, why organizations implement it and how to get started.
You can find the rest of the webinar materials and questions from the webinar here: https://goleansixsigma.com/webinar-introduction-lean-six-sigma/
This presentation is for the personnel who are going to be a part of Six Sigma project as process owner or team member & need to know the basics.
The scope of this presentation is “Overview” & “Define” of Six Sigma.
Learn about the DMAIC method that is used in Six Sigma. This Overview will walk you through Define, Measure, Analyze, Improve and Control in under 5 minutes. Learn more about the DMAIC method and other six sigma techniques on Lean Strategies International LLC's website: www.leanstrategiesinternational.com
DMAIC, which stands for Define, Measure, Analyze, Improve and Control, has provided a structure for process improvement for almost four decades. It’s an easy-to-follow five-step method that works in any industry and on any process. Tune in to this 1-hour Introductory webinar to get a primer on this how this handy model can help you in your quest to improve the world around you.
https://goleansixsigma.com/webinar-introduction-dmaic/
Problem solving road map to guide anybody who must improve a process that is slow, defective, inflexible, unresponsive, costly and risky.
Do you have any like that in your organization?
Of special use for teams following Lean Six Sigma methods (green belt and black belt projects).
Follows DMAIC structure integrated with Lean thinking and tools.
ASSOCIATED KEYWORDS:
Shewhart, Deming, Ohno, Ishikawa, lean, toyota, tps, toyota kata, lean six sigma, project management, six sigma, green belt, black belt, champion, coach, master black belt, deliverables, road map, project management, project plan, DMAIC, LSS, Define, Measure, Analyze, Improve, Control, Sustain, project charter, business case, team, problem solving, milestone, tollgate, baseline, process map, SIPOC, gemba, 7 wastes, 8 wastes, gemba walk, waste walk, spaghetti chart, flow chart, RACI, swimlane, VSM, value stream map, quick wins, operational definition, gage r&r, basic quality tools, check sheet, run chart, histogram, data statification, first time yield, FTY, rolled throughput yield, RTY, COPQ, hidden factory, rework, SPC, Western Electric rules, pareto, prioritization, input, process, output, box plot, scatter plot, correlation, causation, system, 5 whys, cause effect, fishbone, FMEA, hypothesis testing, root causes, quick win, drive out fear, respect for worker, kaizen, 5S, poka yoke, brainstorm, TRIZ, roles, responsibilities, PDCA, PDSA, pilot, roll out, implementation, status, implementation plan, business process management, BPM, KPI, target, performance, response plan, control plan, SOP, inverted pyramid, organization, sustain, plan, budget, communication, training, change, management, adoption, business, capability, prosperity, value, realization, results, replicate, integrate
Lean six sigma - Waste elimination (Yellow Belt)Abhay Yadav
Lean Six Sigma is a methodology that relies on a collaborative team effort to improve performance by systematically removing waste; combining lean manufacturing/lean enterprise and Six Sigma to eliminate the eight kinds of waste (muda): defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, extra-processing
This Lean Six Sigma Yellow Belt Training and Certification Course helps you understand Six Sigma principles, tools, and examples, and do a realistic project in a step-by-step manner.
Lean Six Sigma is a methodology that combines the methods and concepts of Lean Manufacturing with those of Six Sigma. This presentation is a basic overview of the implementation of lean six sigma. Presentation by EMS Consulting Group, Inc. www.emsstrategies.com
Lean Six Sigma is a process improvement methodology that relies on a collaborative team effort to improve performance by systematically removing waste, combining Lean and Six Sigma to eliminate the eight kinds of waste
Lean Six Sigma projects comprise aspects of Lean's waste elimination and the Six Sigma focus on reducing defects
Basic understanding of lean six sigma approach for improvementViral Jain
Before we start working on a project for process improvement.
It is very important to create awareness.
I made this presentation to provide basic understanding of Lean and six sigma.
Usually audience used to be SME, process owner and Higher management people.
After this training ,audience gets a roadmap/ strategy for improvement and how I will help them to improve.
I take their inputs after training and than we start with VOC, VOB and identification of problems and this is how I prefer to start.
During this 1-hour webinar recording, you will receive a basic introduction to what Lean Six Sigma is, why organizations implement it and how to get started.
You can find the rest of the webinar materials and questions from the webinar here: https://goleansixsigma.com/webinar-introduction-lean-six-sigma/
This presentation is for the personnel who are going to be a part of Six Sigma project as process owner or team member & need to know the basics.
The scope of this presentation is “Overview” & “Define” of Six Sigma.
Learn about the DMAIC method that is used in Six Sigma. This Overview will walk you through Define, Measure, Analyze, Improve and Control in under 5 minutes. Learn more about the DMAIC method and other six sigma techniques on Lean Strategies International LLC's website: www.leanstrategiesinternational.com
DMAIC, which stands for Define, Measure, Analyze, Improve and Control, has provided a structure for process improvement for almost four decades. It’s an easy-to-follow five-step method that works in any industry and on any process. Tune in to this 1-hour Introductory webinar to get a primer on this how this handy model can help you in your quest to improve the world around you.
https://goleansixsigma.com/webinar-introduction-dmaic/
Problem solving road map to guide anybody who must improve a process that is slow, defective, inflexible, unresponsive, costly and risky.
Do you have any like that in your organization?
Of special use for teams following Lean Six Sigma methods (green belt and black belt projects).
Follows DMAIC structure integrated with Lean thinking and tools.
ASSOCIATED KEYWORDS:
Shewhart, Deming, Ohno, Ishikawa, lean, toyota, tps, toyota kata, lean six sigma, project management, six sigma, green belt, black belt, champion, coach, master black belt, deliverables, road map, project management, project plan, DMAIC, LSS, Define, Measure, Analyze, Improve, Control, Sustain, project charter, business case, team, problem solving, milestone, tollgate, baseline, process map, SIPOC, gemba, 7 wastes, 8 wastes, gemba walk, waste walk, spaghetti chart, flow chart, RACI, swimlane, VSM, value stream map, quick wins, operational definition, gage r&r, basic quality tools, check sheet, run chart, histogram, data statification, first time yield, FTY, rolled throughput yield, RTY, COPQ, hidden factory, rework, SPC, Western Electric rules, pareto, prioritization, input, process, output, box plot, scatter plot, correlation, causation, system, 5 whys, cause effect, fishbone, FMEA, hypothesis testing, root causes, quick win, drive out fear, respect for worker, kaizen, 5S, poka yoke, brainstorm, TRIZ, roles, responsibilities, PDCA, PDSA, pilot, roll out, implementation, status, implementation plan, business process management, BPM, KPI, target, performance, response plan, control plan, SOP, inverted pyramid, organization, sustain, plan, budget, communication, training, change, management, adoption, business, capability, prosperity, value, realization, results, replicate, integrate
Lean six sigma - Waste elimination (Yellow Belt)Abhay Yadav
Lean Six Sigma is a methodology that relies on a collaborative team effort to improve performance by systematically removing waste; combining lean manufacturing/lean enterprise and Six Sigma to eliminate the eight kinds of waste (muda): defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, extra-processing
This Lean Six Sigma Yellow Belt Training and Certification Course helps you understand Six Sigma principles, tools, and examples, and do a realistic project in a step-by-step manner.
Lean Six Sigma Yellow Belt Certification BrochurePartner
Lean Six Sigma Green Belt Training and Certification Program Brochure by eXample Consulting Group (SMS "leansigma" to 56070 for program schedules or visit http://www.examplecg.com (or) E-mail to sixsigma at examplecg.com)
4. What is Lean Six Sigma?
Lean Six Sigma is the combination of two distinct and complimentary
methodologies with an Enterprise-level perspective
LEAN SIX SIGMA
ENTERPRISE VIEW
SIX SIGMA LEAN
(Reliability) (Simplicity)
Lean Six Sigma 4 Shail Sood
5. Comparing Six Sigma and Lean for process improvement
Six Sigma (Reliability) Lean (Simplicity)
“The relentless effort to systematically
“The relentless effort to systematically
reduce waste while improving the flow of
reduce variation”
value to the customer”
Call Center Example:
Six Sigma would help identify a customer Lean would reduce the length and volume
requirement to answer calls within 19s of calls, decreasing FTE and facility
and ensure 95% of calls are answered requirements
between 0s and 19s
Lean Six Sigma 5 Shail Sood
6. What is “Value-Added”?
Any activity in a process that is essential to deliver the service/product to the
customer.
• Must be performed to meet customer needs
• Adds feature to the service
• Enhances service quality, enables on-time or more competitive delivery, or has a
positive impact on price competition
• Customers would pay for this work if they knew you were doing it
Tip: If it’s not clear whether a task is value-added to your customers, imagine what would
happen if you STOP doing it – would your external or end-customer complain? If so, then
it is likely a value-added activity
Lean Six Sigma 6 Shail Sood
7. What is “Business-Value-Added”?
Activities that are required by the business to execute Value-Added work but do not
add value from an external end customer viewpoint.
Examples: Order entry/processing, entering G/L transactions, etc.
Tip: If you STOPPED doing an activity would your internal customers complain? If
yes, then it is probably Business-Value-Added
Lean Six Sigma 7 Shail Sood
8. What is “Non-Value-Added” or Waste?
Activities that add no value from either the external end customer’s perspective and
are not required for financial, legal, or other business reasons.
Tip: If you STOPPED doing an activity would any customers (internal or external)
know the difference? If not, the work is probably Non-Value-Added
Lean Six Sigma 8 Shail Sood
10. Six Sigma aids in eliminating defects by reducing variability
The objective of a Six Sigma program is to reduce process variation to such a
degree that six sigmas of variation (99.9997% yield) will fit within the specification
limits defined by customers.
Lower Upper
Specification Limit Specification Limit
(LSL) (USL)
Reduce Variation
Losses or
delivered
defects
2
6
Lean Six Sigma 10 Shail Sood
11. Six Sigma DMAIC Approach
Define the Problem
?
1 DEFINE
Maintain gains through Focus the improvement
standardization effort by gathering info
on current situation
5 CONTROL 2 MEASURE
4 IMPROVE 3 ANALYZE
Develop and Implement Identify the Root
Solutions Causes
Lean Six Sigma 11 Shail Sood
12. Six Sigma principles and techniques
Customer Centric Standardized & Repeatable
Focus on customer needs and Reduce variation in products and
requirements processes
Process Focused Training & Change Management
Think process, not function Empower employees
Data Driven Reduce Defects
Focus on facts, not perceptions Seek first pass success
Six Sigma provides methods for reducing process variability
Lean Six Sigma 12 Shail Sood
13. Factors directly impacting the customer’s perception of service quality are
called “Critical-to-Quality” (CTQ) Requirements
Timeliness Responsiveness
Accuracy
Completeness
Quality
Consistency Accessibility &
Convenience
Courtesy
Lean Six Sigma 13 Shail Sood
14. What impact does variation have on a series of dependent events?
Organization / Process
E
A B Y
X
X X
Inputs
F
Products Y
X
Y
C D
X – Input or Process Variable Y – Output Variable
Y = f(x)
Each step (operation) in the process (A, B, C, etc.) don’t always take same amount of time: variability.
E.g., step A takes on average 5 hours +/- 1 hr to complete, step B takes on average 4 hrs +/- 1.5
hrs to complete, etc.
Variability in steps (operations) builds up, variation does NOT balance out, it is amplified! Time to
receive output will have greater variation then the average of each individual steps variation. E.g.,
the total process time will be much greater than the average of each step, with a much greater
overall variability in time than the individual steps.
Lesson: Internal variation does not “average out” and will result in poor output to the customer.
Lean Six Sigma 14 Shail Sood
16. The “Seven Deadly Wastes”
Seven Deadly Wastes
Excessive motion “Chasing” approvals
“Searching” for information
Service Environment Waiting time Waiting for approvals
Meetings and conference calls
Over-engineering Poorly defined or communicated customer
product requirements
Other
Searching for Excess resources lacking clear work activities
information
Unnecessary Corporate policies getting in the way of accomplishing
processing time the tasks at hand
Value-Added Approval
Project Work Wait Time Redundant or unnecessary paper work
Transcribing information multiple times
Meetings and
Conference
~35% Calls Errors Rework
Failing to meet customer requirements
Rework Excessive resources Poor resource leveling to meet demand
Minimal understanding of bottlenecks
Unnecessary Unnecessary approvals
handoffs Verification loops
Lean Six Sigma 16 Shail Sood
17. Becoming Lean
Make the value-creating steps flow
Maximizing value by producing only what is desired in the shortest time possible
with the least resources
Pull to customer demand
Produce at the rate of customer demand only
Pursue perfection
Relentlessly pursue the elimination of waste by empowering employees with waste
elimination tools and entrenching a culture of continuous improvement
Lean Six Sigma 17 Shail Sood
18. Pursuing Perfection – Innovation versus Continuous Improvement
Innovation Continuous Improvement
Innovation involves: Continuous Improvement involves:
great strides, it tends to be abrupt and small steps, it is typically gradual and
volatile constant
the knowledge of a select few individuals input from everyone and significantly less
and requires significant expense expense
Lean Six Sigma 18 Shail Sood
20. Combining Lean and Six Sigma is a combination that drives greater
improvements than either alone
Six Sigma Enterprise Lean
“The relentless effort to systematically “The relentless effort to systematically
reduce variation” reduce waste while improving the flow
of value to the customer”
EPDMEPDM
EPDM Pro
Interlink
Pro E
EPDM
EPDM
EPDM
EPDMEPDM
EPDM Pro EPDM
Interlink
Pro E
EPDM MAC
EPDM
PAC
EPDM EPDM
EPDM EPDM
EPDM MAC
EPDM PAC
EPDM
MAC
EPDM
PAC
EPDM
EPDM
EPDM MAC
EPDM PAC
Simplicity (Lean)
a
Simple, low reliability gm Simple, high reliability
Si Complex, high reliability
Complex, low reliability
ix
/S
CA
DS TS
O
CA C
DS CA OD
CA DS S
DS CO
n
ea
DS
CO C P
DS V S A D
L
R
CO
C
DSA
DS
e
CO
DS CA
ris
DS
CO
DS
CO
MD PA PA
PA A CS
rp
C CO DR CA R
D
D DS
TS S
te
O
E n
Reliability
(Six Sigma)
Lean Six Sigma 20 Shail Sood
21. Lean Six Sigma projects touch all parts of the organization
Cost Productivity
Reduction Improvement
Market-share Growth Customer Retention
Cycle-time Reduction
Error Culture
Reduction Change
Product/Service
Development
Lean Six Sigma 21 Shail Sood
23. Identify Lean Six Sigma projects
First filter: <List all projects>
• Eliminate inconsistencies
• Initial Voice of Customer (VOC), team
experience
<List filtered projects>
Second filter:
• Interviews with key stakeholders to
identify greatest pain points and
opportunity areas
• Surveys with key groups in the <List filtered
organization to identify pain points and projects>
opportunity areas
Final filter:
• Select representative projects
Selected Projects
Lean Six Sigma 23 Shail Sood
24. Document as-is processes of selected projects
Process
E
A B Y
X
Inputs
F
Products Y
Y
C D
X – Input or Process Variable Y – Output Variable
Y = f(x)
Lean Six Sigma 24 Shail Sood
25. Build high level roadmap and milestones (Sample)
Selected Projects Roadmap (2007-08)
1. #Project 1 12/07 1/08 2/08 3/08 4/08 5/08 6/08 7/08 8/08 9/08 10/08 11/08 12/08
2. #Project 2
3. #Project 3 (1) – Production Ready (1) – Marketing, Selling & Ops Support
4. #Project 4
(2) – Production Ready (2) – Marketing, Selling & Ops Support
5. #Project 5
6. #Project 6 (3)- Production Ready (3) – Marketing, Selling & Ops Support
7. #Project 7
8. … (3) – Production Ready
9. …
10. … (5) – Marketing, Selling & Ops Support
(6) – Production Ready
(7) – Production Ready
Milestone
Lean Six Sigma 25 Shail Sood
26. Organization Redesign
• Create a high powered team focused on long-term
Concept value optimization
• Goals and objectives
Team • Roles and responsibilities
Charter • Cross-functional concerns and interdependencies
• Key milestones and measures
• Milestone workplan & critical path
Team • Initial review of initiatives, processes, and
Blueprint technologies
Lean Six Sigma 26 Shail Sood
27. Make sure your resources get what they need or your customers won’t
Hierarchy of Employee Needs
You may recall Maslow’s contention that an Company
individual’s most fundamental needs must Objectives
be met before that individual can focus on
higher order concerns.
Growth &
Career
◊◊◊ Development
Affiliation/place in
the organization and
Start by addressing basic employee needs so cultural fit
they can remain focused on the marketplace
Rewards (compensation
Research shows that employee satisfaction is and benefits), performance
highly correlated with customer satisfaction measures
Security and clarity of employment
status, title, role, leadership structure,
authority, office location, open and
honest communication
Lean Six Sigma 27 Shail Sood