1. Overview of Lean Six Sigma
Presented By The University of Texas-School of Public Health
This 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 Sigma
Compare Lean with Six Sigma to process improvement
Select appropriate phases to apply Six Sigma DMAIC
Methodology
Outline 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 work
Why am I doing what I am doing?
Is it adding value to my client and Fannie Mae?
Gives us practical metrics to evaluate success
Involves you and your team members in creating solutions
How 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 business
Fact-based decision making
Focused on minimizing waste and variation
Focused on strategic business priorities, including the voice of the customer
Works best for narrowly scoped projects
Dedicated resources with clear accountability
Quantified project benefits
Emphasis on sustaining the gains!
Demonstrated track record of success across industries

5. Lean VS. Six Sigma to process improvement
Lean Defined…
Six Sigma Defined… VS
Lean optimizes the process design
Came from process efficiency practices at Toyota
Addresses the fundamental flow of a process
Is a philosophy of continuous improvement that finds and reduces
Wasteful or unnecessary activities
Illogical or inefficient process sequencing
Rework
Excessive cycle times
Lean improvements are typically logical and easy to understand
Lean addresses problems that are
a “mile wide and an inch deep”
Six Sigma is a process improvement methodology addressing defects which arise due to variability in process execution
A defect can be any missed target or
nonconformance to standard
Six Sigma seeks the causes of
variability
Six Sigma projects often apply deep
analysis
Solutions are not readily apparent

6. “Lean Six Sigma” Defined
Lean= efficient process design
Six Sigma= defect-free process execution
“Six Sigma” is a metric used to evaluate the process
Example:
A “defect” is the failure of any process to deliver the intended result
3.4 defects per million opportunities for defects ( % good)

7. Identifying waste and making it visible is the first step
The 5 Principles Of Lean
Elimination of waste Including unnecessary process steps
Lean 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 process
Identifying the value stream for each process
Allowing value to flow without interruptions
Letting the customer pull value from the process
Continuously pursuing perfection
Identifying waste and making it visible is the first step

8. Process Focus Of Lean Six SigmaY
Process
Y = f(x)
Inputs (X1, X2 . . Xn)
Independent
Cause
Control
Output Dependent on input Effect Monitor
Lean focuses on optimizing process design

9. Dynamics Of Execution Strategy
30 – 50 Xs (or more!)
Business Need
Define Phase
Measure Phase
Analyze Phase
Improve Phase
Control Phase
10 – 15 Xs Y
The Funnel Effect
8 – 10 Critical Xs X
4 – 8 Critical Xs
Y = f(X)
3 – 6 Critical Xs
Sustain!
Optimized Process
KPIV = Key Process Input Variable

10. DMAIC Process Define Measure Analyze Improve Control Business Need Y X
Y = f(X)
Control
Sustain!

11. The DMAIC Process Improvement Model2
MEasure
How is the process performing and how is it measured? 1
DEFINE
Who are the customers
And what are their priorities? 5
CONTROL 3
improve
How do we remove the causes
of the defect? 4
Analyze
What are the important causes
of the defect?

12. Confirm the business case for working the project
1. Define Phase
Confirm Process Requirements (voice of customer)
Validate the definition of a “defect”
High level process mapping
Charter the project using metrics aligned with business objectives
Execute “quick wins” when possible
Confirm the business case for working the project

13. 2. Measure Phase
Collect baseline data on project metrics (from the Define phase)
Verify integrity of baseline data for project metrics
Look for patterns in the data
Quantify the historical performance
Begin detailed process mapping
Before trying to “fix” the problem, confirm that you can measure the process

14. 3. Analyze Phase
Apply 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 Xs
Only 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 Phase
Develop potential solutions based on Critical Xs from the Analyze phase
Pilot the “best fit” solution
Plan for full-scale implementation
Solutions are based on findings from the Analyze phase

16. 5. Control Phase Develop Control Plan Implement full-scale improvement
Implement controls
Train personnel and hand-off control plan to Management
Final solution is robust and becomes ingrained in the operation.

17. The DMAIC Process with Tools
DAY 1
Define
1&2
Phase
Tools:
Voice of Customer (VOC) Analysis
Process Mapping
Value Stream Mapping
Measure
Analyze
Improve
Control

18. The DMAIC Process with Tools
DAY 2
Define
3&4
Phase
Tools:
FMEA
Quick Wins 5S
The 8 Wastes
Measure
Analyze
Improve
Control

19. The DMAIC Process with Tools
DAY 3
Define 5
Phase
Tools:
Controls Plans
Lean Visual Controls
Mistake Proofing (Poke Yoke)
Measure
Analyze
Improve
Control

20. Integrating Lean And Six Sigma
Define
Improve
Control
Measure
Analyze
Lean Tools
Six Sigma tools
No matter the nature of a project, value and objectives must be understood
No matter the nature of a project, the process must be measurable
Depending on the nature of a project, Lean tools, Six Sigma tools, or a combination may be best to solve the problem
No matter the nature of a project, the final solution must be controlled.

21. Summary
Lean 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.

22. Thank You