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Lean Six Sigma Overview
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2. Welcome 2
Thank you for participating, Welcome to this Webinar
Today’s Webinar Subject:
Lean Six Sigma Overview
Speaker:
Joe Barckett
Master Six Sigma Black Belt
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3. Joe Barckett – Senior Consultant & 3
Master Black Belt
Significant experience (over 28 years) in the development and
implementation of quality management systems including 6 Sigma &
Lean technologies into top companies within the manufacturing and
service industries.
Held a variety of positions ranging from Quality Statistician, Quality
Engineer, Quality Assurance Manager, TQM Coach and Director of
Quality. As Director of Quality for a $3 billion high-tech Fortune 500
consumer product company, led the organization to ISO 9001
registration and a state Pioneer Award based on the Malcolm Baldrige
National Quality Award criteria.
BS in Mathematics from the University of Massachusetts at Dartmouth,
and MA in Mathematics from Arizona State University.
Served as a Senior Examiner for the 1995 Arizona Governors Quality
awards, and in 1996-1997 for the Massachusetts Council for Quality
award.

4. Webinar Agenda 4
Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up

5. Some SAI Global Six Sigma Results: 5
Manufacturing
Manufacturing
Industry Defect Reduction Monetary Savings
High Tech Manufacturer 92% 250k
Stators Manufacturer -Air
87% 10k
Conditioners
Telecommunications Wire
50% 1.4M
Manufacturer
Telecommunications Wire
70% 100k
Manufacturer
Aerospace Oil Cooler
50% 51k
Manufacturer
Paper Manufacturer 10% 120k
Automotive Manufacturer 90% 72k

6. Some SAI Global Six Sigma Results: 6
Service
Transactional
Industry Defect Reduction Monetary Savings
Service Catalogue Error
86% 170k
Reduction
Out of Stock Product Expedite
61% 500k
Cost Reduction
Back Order Reduction 75% 182k
Service HVAC Calls - Property
38% 166k
Management
Telecommunications Service -- 159k
Telecommunications Service 95% 400k
Telecommunications Service 95% 420k

7. Webinar Agenda 7
Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up

8. Quality Gurus 8
Dr. K. Ishikawa
Dr. Joe Juran
Dr. W. Edwards
Deming
Dr. G. Taguchi
Philip Crosby

9. Similarities 9
Customer focused
Senior management commitment
Culture of continuous improvement
Employee involvement
Process approach
Process improvement methodology: PDCA
Data driven

10. Webinar Agenda 10
Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up

11. History of Six Sigma 11
Dr. Deming Bill Smith Jack Welch
Black ASQ
If Japan … Motorola Belt Certified
PBS/IBM/NBC Wins structure Six Sigma
6/24/80 Baldridge first used Black Belt
1980 1985 1990 1995 2000 2005
Early Adopters Mass Adopters:
and Consultancies including
Transactional and
Supplier Public Sectors
Base

12. What is Six Sigma? 12
1. A summary statistic
2. A process performance metric
3. Philosophy of continual improvement

13. 1. A Summary Statistic 13
Data Set: 0, 1, 2, 2, 3, 4
4 4
3 3
Standard deviation X 2 2 2
1 1
− s, sample standard deviation 0
A deviation!
0
− σ, population standard deviation 1 2 3 4 5 6
Standard deviation is a measure of dispersion that takes into account
each of the data points and their distance from the mean
n
∑ ( X i − X )2
s = i=1
n −1

14. 2. Process Performance Metric 14
Counts
− sigma levels
− dpmo
− ppm or yields
Measure
− sigma levels or z scores
− Process capability
− Cp and Cpk

15. 2. Sigma Levels 15

16. 2. Defects and Sigma Levels 16
A defect is any instance or event in which the product or process fails
to meet a customer requirement.
Sigma Yield DPMO
1 σ 30.85% 691,500
2 σ 69.15% 308,500
3 σ 93.32% 66,800
4 σ 99.38% 6,200
5 σ 99.977% 230
6 σ 99.99966% 3.4

17. 3. Philosophy of Continual Improvement 17
Built into the day-to-day workings of
the company
Everything they do is focused on
improvement

18. 3. Ways to Improve a Process 18
1. Shift the mean
2. Reduce variability
UCL
3. Stabilize over time CL
LCL
4. Capable over time

19. Webinar Agenda 19
Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up

20. 6 Sigma Foundation 20
1. 2.
Process Process
Improvement Design/Redesign
DMAIC DFSS
3.
Process
Management

21. 1. DMAIC: Process Improvement 21
Referred to as continual improvement or incremental improvement:
"recurring activity to increase the ability to fulfil requirements".
Seeks to fix a problem while leaving the basic structure in place.
The emphasis is on finding and targeting solutions to address the
“vital few” factors (the Xs) that cause the problem or pain (the Y).

22. DMAIC Roadmap 22
Validate Estimate
Define Validate Map High
Project State Problem Financial
Scope Level Process
Selection Benefits
Obtain
Identify Select Team Develop
Identify Risk Voice of the D
Stakeholders and Launch Schedule
Customer
Characterize Develop Validate Illustrate
Measure Map Process
Data and Stratification Measurement Baseline and M
with Data
Sampling Plan System Capability
Analyze Value Add Stratification Root Cause Validate Root
A
Analysis Analysis Analysis Causes
Develop
Improve Map New Implement
Potential Pilot Solutions I
Process Solutions
Solutions
Develop Identify Transition to
Control Validate Validate
Sustainability Replication Process C
Improvements Savings
Plan Opportunities Owners

23. 2. DFSS: Process Design/Redesign 23
DFSS: Design For Six Sigma
Often incremental change does not result in breakthrough
improvements
Processes may not be long term capable
Process design/redesign complements process improvement.
The objective is not to “fix” but to “replace” a process or part of a
process.

24. Other Acronyms for DFSS 24
DMADV
− Define, Measure, Analyze, Design, Verify
− Similar to DMAIC approach
IDOV
− Identify, Design, Optimize, Verify
− Focused on final stage engineering optimization
DMEDI
− Define, Measure, Explore, Develop and Implement
− Emphasizes being creative

25. DMADV Overview 25
Define The goals for the design are defined
Critical to Quality characteristics are measured to ensure
Measure
requirements are translated into project goals.
Analyze the options available for meeting the goals. Determine
Analyze
the performance of similar best-in-class designs.
The good/service/process is designed. The design concept is
Design validated using predictive models, simulation, prototypes, pilot
runs, etc.
Verify The design’s effectiveness is verified for its use/operation.

26. 3. Process Management 26
“Process approach”:
− The application of a system of processes within an
organization
− the identification and interactions of these processes, and
their management
Provides ongoing control over the linkage between the
individual processes within the system of processes
Discussed in ISO 9000

27. 3. Process Management (cont.) 27
Processes are documented
Customer requirements are clearly defined
Measures of outputs, process activities, and inputs are
thorough and meaningful
Measures and process knowledge are used to assess
performance in “real time” and take action to address problems

28. Why is 6 Sigma Different? 28
1. Customer focused
2. Bottom line/results focused/partnership with Finance
3. A process not just a set of tools
4. Forces project alignment
5. Data driven/Statistically supported/validated decisions
6. Balances intuition with statistical thinking
7. Includes the whole value chain (SIPOC)
8. Creates true quality metrics (How well)
9. Equally at home in different organizational environments
10. Something in it for employees: certification/a portable skill set
11. Built-in infrastructure
12. Leverages a universal methodology/applied learning
13. Gives permission to improve a process

29. Webinar Agenda 29
Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up

30. “Belt” Roles 30
Project
Belt Training Role
Duration
1. Data analyst
Green Belt 1 week 2. Facilitator
5 to 9 months
(Freshman) (2 week) 3. Project manager
4. Change agent
5. Mentor
Black Belt 5 months to 1
4 weeks 6. Statistician
(Sophomore – Senior) year
7. Program manager
8. Advanced statistician
Master Black 9. Instructor
Belt 1 – 2 years ½ to 2 years
10. Organizational psychologist
(Masters)
11. Integrity and ethics officer

31. Critical Roles and Responsibilities 31
Role Responsibilities
Select projects
Scope projects and write charters
Provide resources and remove roadblocks
Mentor gate reviews
− Understand DMAIC
Sponsor / − Know what questions to ask
Champion
− Recognize tools used
Close projects
Ensure validation of improvements and savings
Ensure sustainability
Replicate opportunities
Celebrate and certify

32. Critical Roles and Responsibilities 32
Role Responsibilities
Own process
Serve on project teams
Process
− At least one core team member must own the process
Owner
− An effort should be made to include all process owners
Sustainability of improvements
Usually a controller or analyst
Financial
Help estimate potential savings
Analyst
Validate project savings
Subject
Leverage special expertise (knowledge, skill, or method)
Matter
Serve as core or extended team member
Experts

33. Sample 6 Sigma Implementation Timeline 33
Month
Activity 1 2 3 4 5 6 7 8 9 10 11 12
Phase 1 Planning
Executive Overview 1 Day
Champion Training 3 - 4 Days
Project Selection
Black Belt Selection
Black Belt Training
Wave 1
4 Weeks
Green Belt Selection
Green Belt Training
Wave 1
1 Week Standard
Project Completion
Wave 1
Phase 2 Planning

34. Webinar Agenda 34
Introduction
Quality overview
Six Sigma overview
Six Sigma terminology and methodology
Six Sigma roles and responsibilities
Wrap Up

35. Wrap Up 35
Increase Revenue
Provide Best Customer Experience
Improve Profitability
Increase Productivity
Create Culture of Performance
Six Sigma Lean
can help with all of these!

36. Contact Us 36
Website:
www.saiglobal.com/training/assurance
Phone:
1-800-374-3818
E-mail for Joe:
Joe.Barckett@saiglobal.com

37. About us SAI Global 37
SAI Global, is an applied information services company, helps you
manage risk, achieve compliance and drive improvement
Sources of
information Applied information services
Publications Compliance Training Assurance
Develop Add value Create & Enhance Assure
and publish through through
Deliver training &
license and distribute awareness independent
standards, consulting assessment
Information communication
services
regulatory, and and monitoring
technical solutions
information

38. About us SAI Global 38
Our Vision Statement:
“To become the premier provider of enhanced and integrated
business management systems that go beyond compliance and focus
our clients on sustainable business performance.”
Our Motto
Semper “Gumby”
“Always Flexible”

39. First Class Registration & Training 39
Registration Services - Merged with QMI, to become QMI-SAI Global to become one of the largest
global registrars
Superior Training and Improvement Solutions - across the United States, Canada and now
Mexico
− Understanding, Implementing and Auditing Training
− ISO Standards, Management Systems and Process Improvement Training across a wide
range of industries and topics
− Food Safety − Medical Device
− ISO 9001 − OHSAS 18001
− ISO 14001 − Automotive
− AS 9100/AS 9110 − Six Sigma and Lean + More
2010 Public Training Calendar - www.saiglobal.com/training/assurance
In-house Training – Courses can be delivered at your premises/preferred location
Commitment to customer and corporate continual improvement
Industry Experts, Trainers and Auditors with over 40+ combined experience
Over 200,000+ people trained worldwide
Successful projects with hundreds of companies
• Focus is achieving ongoing Business Improvement through the use of international standards
as a starting point

40. www.saiglobal.com/training/assurance
40

41. Sampling of Course Offerings 41
• Full curriculum of Six Sigma Lean offerings
• Deploying A Lean Enterprise Initiative
• Continual Business Improvement
• Process Mapping
• Innovation / Creative Problem Solving
• Understanding and Measuring Customer Satisfaction
• Balanced Scorecard
• Effective Corrective and Preventive Action
• Risk Management
• Design Control for the Medical Device Industry
• Skills for Success for the Management Representative
• Process Based Auditing for Business Improvement
• Benchmarking and Measuring Business Performance
• Integrated Business Solutions / Business Excellence

42. Thank you 42
Have a Great Day
Call us - 1-800-374-3818
Email us: training.us@saiglobal.com
Website: www.saiglobal.com/training