Presentation on theme: "Overview of Lean Six Sigma"— Presentation transcript:
1 Overview of Lean Six Sigma Presented By The University of Texas-School of Public HealthThis material was produced under grant number SH SH-1 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.
2 Learning Objectives Define Lean Six Sigma Upon completion of this course, the participant will be able to: Define Lean Six SigmaCompare Lean with Six Sigma to process improvementSelect appropriate phases to apply Six Sigma DMAICMethodologyOutline the integration of Lean and Six Sigma to process improvement
3 How Will Lean Six Sigma Affect You? Enables each of us to lead change by challenging what we do and how we workWhy am I doing what I am doing?Is it adding value to my client and Fannie Mae?Gives us practical metrics to evaluate successInvolves you and your team members in creating solutionsHow does my work affect my customer?How does my work affect other teams (up and down stream)?How can I do it better?Provides new skills for life!The Lean Six Sigma methodology will lead to more meaningful jobs (that bring value to our patients) in a better team environment!
4 What is Lean Six Sigma? Lean Six Sigma is A common improvement methodology to impact the overall businessFact-based decision makingFocused on minimizing waste and variationFocused on strategic business priorities, including the voice of the customerWorks best for narrowly scoped projectsDedicated resources with clear accountabilityQuantified project benefitsEmphasis on sustaining the gains!Demonstrated track record of success across industries
5 Lean VS. Six Sigma to process improvement Lean Defined…Six Sigma Defined…VSLean optimizes the process designCame from process efficiency practices at ToyotaAddresses the fundamental flow of a processIs a philosophy of continuous improvement that finds and reducesWasteful or unnecessary activitiesIllogical or inefficient process sequencingReworkExcessive cycle timesLean improvements are typically logical and easy to understandLean addresses problems that area “mile wide and an inch deep”Six Sigma is a process improvement methodology addressing defects which arise due to variability in process executionA defect can be any missed target ornonconformance to standardSix Sigma seeks the causes ofvariabilitySix Sigma projects often apply deepanalysisSolutions are not readily apparent
6 “Lean Six Sigma” Defined Lean= efficient process designSix Sigma= defect-free process execution“Six Sigma” is a metric used to evaluate the processExample:A “defect” is the failure of any process to deliver the intended result3.4 defects per million opportunities for defects ( % good)
7 Identifying waste and making it visible is the first step The 5 Principles Of LeanElimination of waste Including unnecessary process stepsLean techniques are used to reduce unnecessary steps, eliminate rework, save time, save cost and extend capacity of valuable resources by:Specifying the value of the processIdentifying the value stream for each processAllowing value to flow without interruptionsLetting the customer pull value from the processContinuously pursuing perfectionIdentifying waste and making it visible is the first step
8 Process Focus Of Lean Six Sigma YProcessY = f(x)Inputs (X1, X2 . . Xn)IndependentCauseControlOutput Dependent on input Effect MonitorLean focuses on optimizing process design
10 DMAIC Process Define Measure Analyze Improve Control Business Need Y X Y = f(X)ControlSustain!
11 The DMAIC Process Improvement Model 2MEasureHow is the process performing and how is it measured?1DEFINEWho are the customersAnd what are their priorities?5CONTROL3improveHow do we remove the causesof the defect?4AnalyzeWhat are the important causesof the defect?
12 Confirm the business case for working the project 1. Define PhaseConfirm Process Requirements (voice of customer)Validate the definition of a “defect”High level process mappingCharter the project using metrics aligned with business objectivesExecute “quick wins” when possibleConfirm the business case for working the project
13 2. Measure PhaseCollect baseline data on project metrics (from the Define phase)Verify integrity of baseline data for project metricsLook for patterns in the dataQuantify the historical performanceBegin detailed process mappingBefore trying to “fix” the problem, confirm that you can measure the process
14 3. Analyze PhaseApply non-statistical techniques to brainstorm potentially critical Xs which may be driving variability in the project metrics (again from the Define phase)Apply statistical techniques to investigate the potentially critical XsOnly after completing Define and Measure do you begin the detailed investigation into Critical Xs
15 Solutions are based on findings from the Analyze phase 4. Improve PhaseDevelop potential solutions based on Critical Xs from the Analyze phasePilot the “best fit” solutionPlan for full-scale implementationSolutions are based on findings from the Analyze phase
16 5. Control Phase Develop Control Plan Implement full-scale improvement Implement controlsTrain personnel and hand-off control plan to ManagementFinal solution is robust and becomes ingrained in the operation.
17 The DMAIC Process with Tools DAY 1Define1&2PhaseTools:Voice of Customer (VOC) AnalysisProcess MappingValue Stream MappingMeasureAnalyzeImproveControl
18 The DMAIC Process with Tools DAY 2Define3&4PhaseTools:FMEAQuick Wins 5SThe 8 WastesMeasureAnalyzeImproveControl
19 The DMAIC Process with Tools DAY 3Define5PhaseTools:Controls PlansLean Visual ControlsMistake Proofing (Poke Yoke)MeasureAnalyzeImproveControl
20 Integrating Lean And Six Sigma DefineImproveControlMeasureAnalyzeLean ToolsSix Sigma toolsNo matter the nature of a project, value and objectives must be understoodNo matter the nature of a project, the process must be measurableDepending on the nature of a project, Lean tools, Six Sigma tools, or a combination may be best to solve the problemNo matter the nature of a project, the final solution must be controlled.
21 SummaryLean Six Sigma gives you practical metrics to evaluate success in the context of corporate objectives.Lean Six Sigma is used to reduce unnecessary steps, eliminate rework, save time, save cost and extend capacity of valuable resources.Five phases of DMAIC process is define, measure, improve, analyze, and control.