1) The document outlines objectives and tools for a process improvement workshop including Lean, Six Sigma, and Theory of Constraints methodologies. 2) It discusses defining and mapping current and future process states to identify waste and maximize value using tools like value stream mapping. 3) The goal is to eliminate waste and variation to improve processes by 25% or more and support continuous learning.

1. Process Improvement Workshop Scott Miller [email_address] 937-781-1068 Dan Dupree [email_address] 937-781-1061 Learn. Perform. Succeed.

2. Workshop Objectives Philosophies Tools Applications Soft Skills

3. Process Improvement Many complementary philosophies. Lean emphasizes minimizing waste and adding value for the customer Six Sigma emphasizes minimizing variation and eliminating defects Theory of Constraints emphasizes identifying and removing bottlenecks

4. Keys to Successful Implementation Journey Mindset Visible Leadership Support Mutual Trust Aligned Reward System This is a Culture Change

5. Process Defined Any activity that takes inputs, performs actions on the inputs, and results in outputs Process Action Inputs Materials People Equipment Data Outputs Product Service

6. Three Views of a Process Policy (documented) Leadership View as applied What is really happening

7. Value Stream Analysis (a useful tool)

8. Define the Boundaries What is the process? Where does it start? Where does it end? What do you control? What can you influence? What do you need to adapt to? Depends on your perspective

9. Value Stream Mapping Define the boundaries “ Walk” the process Identify tasks and flows of material and information between them Gather data Identify resources for each task and flow Create the “Current State” map

10. Analyze Current Conditions Identify value added Identify waste

11. Voice of the Customer What does the customer want? What will the customer trade resources to get? Money Time People Not what we say we can deliver because of our current approach

12. Value Defined Value-Added Activities Transforms or shapes material or information Customer wants it Done right the first time Non-Value Added But Required No value created but required by current technology No value created but required by current thinking No value created but required by process limitations Waste Consume resources but create no value for the customer Pure waste

13. Eliminate Waste Types of Waste Defects Over Production Transportation Movement Waiting Inventory Over Processing Lost Creativity

14. Lean Emphases Resource distribution Opportunity for improvement by reducing waste and creating additional value Value Waste Initial Process Value Waste General Process Reduction Reduce all processes by 25% Waste and Value Both Decrease Waste Only Reduction Value Waste Target & Reduce Waste Maintain Value Value Maintained Resources Decrease Value Creation Value Waste Apply Resources to Create More Value Value Increased Resources Focused

15. Visualize “Ideal State” What if there were no restrictions?

16. Doing what you’ve always done and expecting different results INSANITY

17. The MindShift Model Extracted from The 7 Levels of Change by Rolf Smith1997 Do Different Mindshift Different Results Think Different Mindshift Think About Thinking Mindshift

18. Create “Future State” Map Change the process Eliminate waste Maximize value

19. Change Up ‘Til Now…. From Now On….

20. Value Stream Mapping Define the boundaries “ Walk” the process Identify tasks and flows of material and information between them Gather data Identify resources for each task and flow Create the “Current State” map Define the value Analyze current conditions Identify value added Identify waste Visualize “Ideal State” Create the “Future State” map Change process to eliminate waste and maximize value Develop action plans and tracking

21. ositive nteresting hallenges P I C

22. LEVELS OF CHANGE LEVEL 7: Breakthrough-Doing things that can’t be done LEVEL 6: Different-Doing things not done before LEVEL 5: Adapting-Doing things other people are doing LEVEL 4: Cutting-Doing away with things LEVEL 3: Improving-Doing things better LEVEL 2: Efficiency-Doing things right LEVEL 1: Effectiveness-Doing the right things Extracted from The 7 Levels of Change by Rolf Smith1997

23. Lean and Six Sigma Lean and Six Sigma are complementary process improvement philosophies. Lean emphasizes minimizing waste and adding value for the customer Six Sigma emphasizes minimizing variation and eliminating defects

24. Statistically Speaking… Variation is the difference between the actual value and what that value was expected (or desired) to be. The Standard Deviation (Sigma (  )) is a quantitative measure of the variation of individual data items about the mean (expected value) of those items. People notice variation.

25. 1 part per billion falls outside limits 1,350,000 parts per billion fall outside limits In this example, the same number of occurrences are measured. The top curve represents a 6  process, the lower curve represents a 3  process The lower curve (red) represents a process with a standard deviation of 8 units. The specification limits for this represent a 3  process The upper curve (blue) represents a process with a standard deviation of 4 units. Since variation is reduced compared to the lower curve, within the same specification limits, this is a 6  process Specification limits (the values defining the range of acceptable quality)  = 4 -24 +24  = 8 2  1  3  4  5  6  -5  -6  -4  -3  -2  -1  2  1  3  4  5  6  -5  -6  -4  -3  -2  -1  -24 +24 Mean

26. 5S Overview Simplify Shine Sort Standardize Sustain Safety

27. DAU Continuous Learning Center https://learn.dau.mil/html/clc/Clc.jsp select the "Course Information & Access" link. CLE 004, Introduction to Lean Enterprise Concepts CLE 008, Six Sigma: Concepts and Process CLE 007, Lean-Six Sigma CLE 001, Value Engineering. CLE 015, Continuous Process Improvement Familiarization.

28. Thank you for Participating Scott Miller [email_address] 937-781-1068 Dan Dupree [email_address] 937-781-1061 Learn. Perform. Succeed.