Presentation on theme: "Guide to Business Improvement Tools"— Presentation transcript:
1 Guide to Business Improvement Tools LEAN MANUFACTURING&SIX SIGMA
2 Contents Overview of LEAN Manufacturing Overview of Six Sigma PDCA WheelSix Sigma RoadmapTool selection guide
3 LEAN ManufacturingHenry Ford production line to Toyota Production SystemMethodology spread across industries and countriesProduction activity that is not important to the customer is seen as waste, and to be reduced / eliminated.Focuses on optimising ‘production flow’ .Converts ‘push through to sell’ production to ‘pull through by customer demand’ production.
4 PDCA WheelA foundation tool of LEAN to explain to teams how to make process improvements.Plan the improvementDo the trialCheck the resultsAction the new standardOnce the new standard is locked in, further improvement activity can occur
5 Six Sigma ( 6σ )Created by Motorola in the 1970’s in response to quality criticismsHeavy on Statistical Process Control and Hypothesis testingFocus is to reduce defects by reducing process variabilityQuality side toolsAcceptance side toolsA 6σ process is % accurate(Between three and four defects per million opportunities)Excellence = Quality x Acceptance
6 Six Sigma DMAIC Roadmap DefineMeasureAnalyseImproveControlA. Project Blitzedadded toBCSPipeline1Business Case and draft Charter into Project Pipeline in BCS5Validate Measurement System13Identify & Select Potential Solutions8Develop data collection plan around key x’s;12Practicallyvalidate root causes11Graphically & Statistically validate root causes9Implement & ControlQuick Wins16Demonstrate final capability and control plan effectiveness$2Project Selected andProject Leadership Team SelectedI -1Stakeholder check-in Q-A Solutions Approved6Confirm Current Process Performance10Collect data around key x’s17Final sign off by Process Owner$B. Project KickoffMove to Investigation Phase14Develop Implementation Plan, Control Plans and process control systemProject Completed3Check and Learn from previous work7Identify key x’s&Quick winsStartProjectCycle timeEnd ProjectCycle time18ShareLearnings;Replication ,Report, Poster$I -2Stakeholder check-in Implementation Approved4Align Team & confirm Project Charter19Celebrate Improvements and Recognise Team$C. End Investigation Cycle timeCycle time 1DStakeholder check-in Charter ConfirmedMStakeholder check-in AStakeholder check-in 15Implement Approved Solution(s) and Control PlansBeltPOPL or MgmtPrimary Responsibility ofRev v10 ARequired Financial review (BCS entry)$
7 Six Sigma / Lean Define Measure Analyse Improve Control Desired OutcomesSix SigmaTools to UseLeanTools to UseDefineConfirmed CharterMobilised TeamEngaged StakeholdersACtE, VOC, CTQ, SIPOC, In/Out, Project ChartersProject Chartering, Value Stream, Theory Of Constraints, Yield, Rolled Throughput YieldMeasureProcess CharacterisedData ValidatedCapability Analysis on Y outputACtE, MSA,XY, FMEA, Process Map, Data Collection PlanInterview & Observation, 5S, Time & Motion, VSM VA / NVA, Flow Charting, Base Line Analysis, Spaghetti Diagrams.AnalyseUncover Root CausesACtE, Hypotheses testing, Multi Vari, Control Charts, FMEATakt Time, Multi Cycle Analysis, Root Cause ID, Defect AnalysisImproveSolutions SelectedImplementation PlanCommitted StakeholdersACtE, DOE, BOA, Training, Change MgmtSMED, Quick Changeover, Load Balancing, Kanbans, SimulationMultiskilling, Mistake ProofingControlTransition to OwnerProcess Control SystemKnowledge SharingACtE, Control Plans, SOP, SPC, Control Charts, Action Plans5 S Discipline, Standard Work, On time delivery, Perform to Takt TimeAligning Commitment towards Excellence (ACtE) supports all stages of the process!