1. Self Directed Work Teams
Lean Six Sigma in a Self Directed Work Force

2. GE … a tradition of excellence
Founded in 1878 as the Edison Electric Co.
130 years of successful operation
300,000+ employees worldwide
Strong technology focus … Research centers in Germany, India, China and the U.S.
First Carbon Filament Light Bulb, 1879 2

3. A heritage of innovation
1879 Thomas A. Edison invents carbon- filament incandescent lamp
1913 Develops X-ray tube & first commercially practical X-ray device
1941 Develops first US jet engine
1952 Develops LEXAN® polycarbonate resin—a transparent plastic
1962 GE invents solid state laser
1983 Develops magnetic resonance imaging
2004 Introduces the GE90-115B, the world’s most powerful jet engine
GE founded in 1878 as Edison Electric Company … Today 300,000+ employees and $173 billion revenues

4. Why 6s ? Jack Welch’s “Vision 2000”
“Quality is the next opportunity for our Company to set itself apart from its competitors . . .
... Dramatically improved Quality will increase employee and customer satisfaction, will improve share and profitability, and will enhance our reputation.
... This Quality drive will require the passionate commitment of all of you to make it happen A Six Sigma 2000 target will require a significant commitment of resources and your strong, highly personal commitment to the objective.”
J.F. Welch, 10/15/95

5. In the end you need both to create a world-class business.
Lean and Six Sigma
Two separate improvement approaches…
They both can help you improve your processes. Depending on what you want to improve, you either choose one of the two or both.
…that are strong together
Six Sigma can help Lean to reduce waste by improving the process capability in processes in the value stream.
Lean can help Six Sigma to increase process capability by eliminating waste in processes.
In the end you need both to create a world-class business.

6. Self Directed Work Teams
“Increasing employee involvement through self-directed work teams is not only a good thing to do, it is a business thing to do.”
Ron Williams, 3M Quality Manager
Greater Flexibility
Reduced Operating Costs
Faster Response to Change
Fewer, Simpler Job Classifications
Better Response to Workers’ Values
Increased employee commitment to the Organization
Ability to attract and retain the best people

7. GE Durham Paintfest Staff Team building at Jordan Lake
Health Awareness Day
Durham Bulls Day
Kids to Work ‘08
Durham Family Day Sept’08
Special Olympics Plane pull at RDU ‘08

8. Durham’s History ‘93 ‘94 ‘99 ‘02 ‘03 ’04 ‘08
Constructed in 1972 for GE Energy PS Steam Turbines
500 acres of land
500,000 sq. ft. of floor space
Site
opened
for
assembly
of aircraft
engines
DEF ships
first GE90
&
CF6-80C2
DEF ships
first
CFM56-7
&
CF34-8C
GE90-115B
CF34-8D/E
CFM56-5
CF34-10
GP7000
CF6-80C2 L1F
LMS100
GEnx
‘ ‘ ‘ ‘ ‘ ’ ‘08

9. Growth thru Lean Zero Additional Footprint & Double Digit Productivity
Engine Output
1995
1997
1999
2001
2003
2005
2007
2009
Zero Additional Footprint & Double Digit Productivity

10. Commercial Products GEnx GE90 GP7200 Support CFM56-5/7 CF34-10 CF34-8
Horizon
Raven Synergy Heritage
Support
GEnx
GP7200
CF34-10
CF34-8
CFM56-5/7
Liberty
Odyssey
Phoenix
Freedom
Summit
Apollo
Intrepid
Mirage

11. High Performance Team Flat Organization Self Directed Workforce
Flexible Culture
Multi-skilled Talent
Boundryless Structure
Improvement Driven Culture
Odyssey Apollo Summit GP7200 Intrepid Mirage Freedom
Raven Heritage Synergy Horizon Phoenix Liberty GEnx

12. Councils..Facility Wide Decisions
People
Processes
Human Resources
Discipline & Development
Training
Tool & Gauge
Materials
One Representative per team
Rotate members every 12 months
Weekly Meetings
Quality
Safety
Quality Systems
Nonconforming
Delivered Quality
Environmental, Health
& Safety

13. Technician Deliverables
Assemble Engines
Meet business objectives
Track incoming material shortages
Develop schedules to meet ship dates
Create & maintain operation planning
Acquire tools & components
Coach & train other team members
Ensure quality of parts & engine build
Perform inspections
Ship to Peebles Test Operation
Conduct post-test fault reviews

14. Technician Growth Opportunities
Tech III
Advanced Assembly Skills
Machining
Computer Systems
Personal Development
Business Initiatives
Personal Logbook
Assessment Process
Tech II
Advanced Assembly Skills
Machining
Tech Writing
Personal Development
Computers
Quality Systems
Leadership Roles
Tech I
Basic Assembly Skills
Finance
Computers
Team Building Skills
Quality Systems
EH&S
Compliance
Tech
Two-week training before build
Extensive training matrix
“P” License Required
> 9 months
< 9 months
< 2 year
< 4 year
Pay Increase with Achievement of Each Level

15. Communication Tools Communication Training Customer Visits Videos
& Voic
DEF Business Review

16. Flexibility Multi Skilling Flex Time PB Days 360 Feedback
Extensive Training

17. Double digit productivity
Continuous Improvement
Culture
Safety
Zero Injuries
Double digit productivity
Results
Lean Six Sigma
Quality

18. GEnx Flow Line 250% Reduction in Footprint & Utility Costs Summer ‘07
1/8th Scale Model
Today
250% Reduction in Footprint & Utility Costs

19. Team Metrics… Drive Accountability
Reward & Recognize

20. Our Workplace Community
Team Cookouts
Xmas Lunch
GE Volunteers
“Family Feud Game”
Team Competitions
Veterans Day
Casino Night
Qtr Point Celebration