Presentation on theme: "Antti Kontio (22.01.2003) AGENDA FOR 6S COUNCIL EUROPE 3.4.2003 PROGRESS IN IMPLEMENTATION GB TRAINING ONGOING PROJECTS OPERATING PLAN VISION 1,3,5 YEARS."— Presentation transcript:
Antti Kontio ( ) AGENDA FOR 6S COUNCIL EUROPE PROGRESS IN IMPLEMENTATION GB TRAINING ONGOING PROJECTS OPERATING PLAN VISION 1,3,5 YEARS NEXT STEPS PROPOSAL FOR MASTER THESIS SUBJECT: – QUALITY COST (COPQ) COUNTING AND REPORTING SYSTEM AND PROCEDURES TO DRIVE SIX SIGMA PROJECT SELECTION
Antti Kontio ( ) TARGETS 2003 EUROPE Benefits from 6S projects = € (Benefits/costs=3.5) 18 Green belts trained (5 Lahti, 5 Hollola, 2 Laitila, 2 Tooling, 2 Helmond, 2 Pécs) 30 Greenbelt projects finished by or € 6 Black belt projects finished by or € Training material created for GB and awareness training Define procedures how individual 6S projects will be reported so that the results can be utilized throughout whole company
Antti Kontio ( ) 6S OPERATIONALIZING PLAN EUROPE TARGETS/ EXPECTATIONS 6S+MBB ASSESSMENT+ REVIEW FEEDBACK FROM GE/Marcel Present state analysis Benchmarking 6S council+BBs MEASUREMENT+ TRACKING REWARD EARLY SUCCESS COACHING SUPPORT INFRASTRUCTURE RESOURCES TRAINING REPORTING DEPLOYMENT INITIAL PLAN IMPROVE DEPLOYMENT PLAN SIX SIGMA VISION +NEED FOR 6S PROJECTS TARGETS/ EXPECTATIONS FOR BB+GB COST OUT YIELD… 6S COUNCIL CHAMPIONS ON BOARD MBB NETWORK GE SUPPORT 2 BBs Kim + Wille Choosing 5 GB’s/Plant GB Training Awareness training CAP for BBs DFSS/DMAIC Project selection Assign high leverage projects for BBs+GBs Ensure early wins MBB coaches + facilitates BBs + GBs Results reported to 6SC Reward good results successes training/project completion REPORT TO 6SCOUNCIL+PVI ASSESSMENT CRITERIA Measure progress NEXT PROJECTS TRANSLATE RESULTS P A C D 1st Wave
Antti Kontio ( ) PROGRESS IN IMPLEMENTATION 21 GB selected (9 Lahti, 5 Hollola, 2 Tooling, 1 Laitila, 3 Helmond, 1 Pécs) 18/21 GB’s have project GB training material for 1st module created 1st module of GB training (Jan Martens/GEP, AK, WV as trainers) Supporting Kim, Wille, Janna and Johanna Annual plan created years vision created Quality research =>results by 11.4, America+Europe+China next
Antti Kontio ( ) GB PROJECTS
Antti Kontio ( ) ONGOING BB PROJECTS Wille – Vanessa A+B combinations =>testing+analyzing – Jacqueline A+B USW and combinations =>testing+analyzing – A new project is needed Kim – Foil positioning improvement in Jacqueline window =>Target finished at W17 – Starting project: Bright dots in IMD process Janna – DFSS: 2S IMD Window in Hitchiker Johanna – DFSS: Implementing SPC Development team projects 3 large BB projects (Niina)
Antti Kontio ( ) OPERATING PLAN
Antti Kontio ( ) CURRENT STATE ANALYSIS – INDIVIDUAL LEVEL PLAYERSNumber of players 1 st project2nd project5th projectExperiencedGuru MBB11 BB- done own projects 321 BB – Coached GB’s 0 GB20 CHAMPIONS?
Antti Kontio ( ) DMAIC DFSS LEAN SIX SIGMA Some experi- ence Six Sixma Institu- tionalized CAP No experi- ence Experi- ence Six Sigma Excel- lence BB SIX SIGMA CAPABILITY CURRENT STATE ANALYSIS NOW 1 YEAR 3 YEARS 5 YEARS
Antti Kontio ( ) DMAIC DFSS IMD Painting Injection molding IML Pad printing BB USW insert Assembly SCM Bezel Assembly SPC PROCESSES WHERE 6S HAVE BEEN APPLIED
Antti Kontio ( ) COPQ REPOR- TING AND SELECTION CRITERIA 6S- TRACKER SOFT- WARE CTQ FLOWDOWN FROM COMPANY GOALS PROJECTS CHOSEN BASED ON FEELING OR EMERGENCY PROJECTS CHOSEN BASED ON FACTS Important There are projects Number of projects Important Impact of project Important CTQ alignment with company goals and external CTQ’s Project scope Single product or part of simple process Production processes Project scope In addition: Complete processes, technologies, design and verify new processes, SCM, lean, factory level projects Translating results Create and disseminate best practices Project scope In addition: Mission critical projects Projects derived directly from goals SIX SIGMA AT SUPPLIER/ CUSTOMER INTERNAL FOCUSALSO EXTERNALLY
Antti Kontio ( ) SIX SIGMA VISION 1-YEAR (2003) – Re-implementation of Six Sigma – Company level: Beginning 6 BB projects, 30 GB projects, 5 DFSS projects – Simple projects, single product/part of simple processes, production projects, some DFSS projects – Beginning to use Six Sigma metrics and reporting – Individual level: Beginning mainly 1-3 project experience for GB’s and BB’s, people need lot of support and coaching – COPQ (+cost/benefit) counting and reporting implemented to drive six sigma project selection – Rigorous review process implemented – 1st GB training organized => 20 GB trained people – Awareness of people have been raised – basic understanding 3-YEAR (end of 2005) - Institutionalizing – Company level: Experience from over 100 projects – Complete processes, technologies, design and verify new processes, SCM, lean, factory level projects, translating results – Create and disseminate best practices throughout EIMO – Six Sigma targets are aligned with company goals and CTQ’s – Some experience with Six Sigma at supplier/customer – Six Sigma Cook Book created – Individual level: 20 GB’s with more than 10 projects experience, GB some with 5 project experience, some in the beginning, 3-5 BB’s with more than 10 project experience – Reporting COPQ, improvement results etc. part of daily life – Capability to train all Six Sigma tools and resources internally – Six Sigma awareness training part of new people introduction, all people have basic understanding – Systematic career development for Six Sigma people – Six Sigma has been institutionalized and has gained wide acceptance as key improvement methodology – Benefit/cost ratio >4 5-YEAR (end of 2007) – Excellence in Six Sigma – Company level: Experience from over 200 projects, 6S widely applied throughout company – Capability to execute Six Sigma improvement widely in all processes (business and manufacturing) – Benchmarking and disseminating best practices widely in use – Metrics and reporting systems extensively used and understood throughout company
Antti Kontio ( ) COPQ/COST/BENEFIT COUNTING/TRACKING SYSTEM Proposal for Master thesis subject Define what and how (principles) will be counted for e.g. – Internal COPQ (Scrap, rework, inspection, downtime, delivery inaccuracy, capcity loss…) – External COPQ (Reclamations, …) How COPQ will be reported – By products – By processes – By teams – By technologies – Daily, weekly, monthly… – Where this information can be mined – Define who should be interested in COPQ – What system is used in reporting =>Power Play Procedures how COPQ information drives Six Sigma project selection – We wiil be able to choose BB-projects that have biggest impact – We will be able to choose smaller (more manageable) projects for GB’s Procedures how to report impact of Six Sigma projects –We will be able track and report impact of 6S projects (cost/benefit info)
Antti Kontio ( ) NEXT STEPS GB training module 2 Champion awakening training, choosing champions Project selection procedures (Antti, Niina, Marko) Start COPQ counting/reporting project (MSc thesis??) GB project definitions Project review&progress control with Kim, Wille, Janna, Johanna and GB’s Awareness training Create visibility for Six Sigma =>News letter, awareness training, 6S afternoon
Antti Kontio ( ) DMAIC DFSS LEAN SIX SIGMA Simple process Compli- cated process CAP Product Techno- logy SIX SIGMA AT CUSTOMER SIX SIGMA AT SUPPLIER x BB GB MBB GB BB MBB BB SIX SIGMA – WHO DO WHAT?
Antti Kontio ( ) SIX SIGMA EUROPE ORGANISATION 6S COUNCIL EUROPE MBB+CHAMPIONS LAHTIHOLLOLATOOLINGHELMONDLAITILAPÉCS BB GB MBB+CMBB+C OPERATIONALIZING + 6S STRATEGY SUPPORTSUPPORT BB Janne Martin?Katja Äärilä? Timo Seppä Seppo Jaakkola Petri Virtanen Minna Alitalo Marko Salli Kim GustafssonWille ViittanenM.S./F.N/H.N?
Antti Kontio ( ) HOW TO TRACK PROGRESS FEED BACK/REVIEW MECHANISM – Regular 6S council meetings timetables agreed => 1/month – Suggested agenda for meetings – Progress against operationalizing plans, achievements and concerns – Status of 6S projects, achieved results – Visitor presenting his/her project – Recognition – New ideas for 6S projects – Input to future plans – Other, what? – MBB reviews BB and GB progress 1x/1-2 weeks – Agenda for meetings – BB+GB meeting 4x/year => for developing our Six Sigma approach and share experiences – MBB team meeting (Eimo, Fibox, Lego, Grundfos) – Reporting to Pete – GE Support/Mentoring
Antti Kontio ( ) HOW TO TRACK PROGRESS – STATUS OF ALL PROJECTS PROJECT CHARTER
Antti Kontio ( ) HOW TO TRACK PROGRESS – INDIVIDUAL PROJECTS
Antti Kontio ( ) SELECTING+TRAINING GB’s 18 Green belts trained (5 Lahti, 5 Hollola, 2 Laitila, 2 Tooling, 2 Helmond, 2 Pécs) Internal search =>how? =>Virpi Requirements: – Selfmotivated, interest towards improvement/6S – Possibility to do GB projects also after training – Basis OK (English, computers, preferably knowledge of production and/or improvement, studies) – Diversified group of people (mold, injection, painting, assy…) – Short interview Production managers to champion course Management participation (at least opening and closing sessions)
Antti Kontio ( ) TRAINING PLAN Choose 5 GB’s for Lahti and Hollola, 2 for Tooling, 2 for Laitila, 2 for Helmond, 2 for Pécs =>18 GB’s Training: – selfstudy CD-ROM/digital training – 2 x 2 days GB training at Lahti Trainers: – Marcel Kranenburg/GE – Antti Kontio MBB, Wille Viittanen+Kim Gustafsson BB Time: – 1st training week 11 ( ) in Lahti =>check winter holiday plans – 2nd training week 14 ( ) – 3 weeks of project work between training Projects must be selected for participants =>1st priority 1st 2 days is introduction to Six Sigma, DMAIC and 12-steps, some 6S Tools 2nd 2 days going into tools, DMAIC steps 1-3 must be completed before joining 2nd training
Antti Kontio ( ) WHERE PROJECTS COME FROM Big strategic projects? =>6S COUNCIL BB projects? Co-ordinated by Antti GB projects? Co-ordinated by Antti Development/R&D 6S projects? =>Niina Pareto projects –they are working well in Hollola with Kim and Tomi =>continue with them What to do when there is lack of BB’s or GB’s? How to get initiatives? How to process initiatives? How to reward initiatives?