Intro to LSS1 LSSG Green Belt Training Introduction to Lean Six Sigma

Intro to LSS2 Who is Responsible for LSS? CHAMPIONSenior manager responsible for overall success of project. MASTER BLACK BELTTrain/coach/mentor BBs, monitor progress. BLACK BELTFull-time LSS employees, Lead, track project, mentor GBs. GREEN BELTWork part-time on LSS in their work areas. OTHER BELTSTeam Members, Data Collectors, Subject Matter Experts (SMEs). Defining Roles and Responsibilities

Intro to LSS3 Deming’s 14 Points W. Edwards Deming ( ) 1. Create constancy of purpose for improvement 2. Adopt a new philosophy 3. Cease dependence on mass inspection 4. Do not award business on price alone 5. Work continually on the system of production and service 6. Institute modern methods of training 7. Institute modern methods of supervision of workers 8. Drive out fear 9. Break down barriers between departments 10. Eliminate slogans, exhortations, targets for the work force 11. Eliminate numerical quotas 12. Remove barriers preventing pride of workmanship 13. Institute a vigorous program of education and retraining 14. Take action to accomplish the transformation

Intro to LSS4 Sigma (  ) vs Sigma Level  = Standard Deviation a measure of variation around the average Sigma Level = 1/2 the number of standard deviations (  ) that will fit between the specification limits when the process is centered   Customer Specifications = 8/2 = 4  = 12/2 = 6  Sigma level is also a measure of the number of defects per opportunity produced by a process.

Intro to LSS5 Six Sigma Improvement Methods Define Measure Analyze Design Validate Improve Control Six Sigma accommodates both Improvement and Reengineering

Intro to LSS6 Six Sigma Improvement - Role of Tollgates Ensure Sequence Obtain formal approval to move to the next DMAIC phase Prevent team from skipping steps Enable Communication Provide management with project updates at each level Allow Charter Updates Make modifications to project scope Define Measure Analyze Design Verify Improve Control

Intro to LSS7 DMAIC Six Sigma - Define Objectives Identify Customers Complete Charter Understand Process Measure Control Analyze Improve Define Tools Charter, VOC, VSM, CTQ SIPOC, Scorecards

Intro to LSS8 DMAIC Six Sigma - Measure Objectives Identify Inputs and Outputs Measure Process Capability Revise Charter Measure Control Analyze Improve Define Tools Brainstorming, MSA, Walkthrough, C&E, 5S, KPOV, KPIVs, RTY, Benchmarking

Intro to LSS9 DMAIC Six Sigma - Analyze Objectives Determine Variation Sources Prioritize Key Outputs and Inputs Revise Project Benefits Measure Control Analyze Improve Define Where are the key leverage points for driving breakthrough performance? Tools Fishbone Diagram, Pareto Chart, Process Capability, Control Charts, Layout and Process Flow Analysis FMEA, Statistical Analyses

Intro to LSS10 DMAIC Six Sigma - Improve Objectives Develop Potential Solutions Develop Future State Evaluate and Mitigate Risk Measure Control Analyze Improve Define How do we get there? Tools Kaizen Event, Contingency Planning, Pilot, DOE, Optimization.

Intro to LSS11 DMAIC Six Sigma - Control Objectives Implement Controls Standardize Evaluate Benefit Measure Control Analyze Improve Define Tools Standardization, Training, Visual Aids, Mistake Proofing, Documenting Benefits How Do We Keep the Gains?

Intro to LSS12 DMAIC Six Sigma - Design Objectives Design Product/Process Evaluate Product/Process Structure Evaluate Risk/Benefit Measure Verify/ Validate Analyze Design Define How do we create and implement a new process that will delight the customer and provide outstanding business results?

Intro to LSS13 DMAIC Six Sigma - Verify Objectives Beta test Plan Implementation Implement Solution Measure Verify / Validate Analyze Design Define How do we determine if the new process is successful?

Intro to LSS14 What is Lean? Elimination of Non- Value Add Activity Customer Pull Genuine Focus on the Customer Culture for Lean Lean Tools, Methods and Measures Kaizen Events JIT Delivery Increase Offering/Decrease Changeover Visual Management LEAN - Like water running downstream - more speed with less effort! Continuous Flow

Intro to LSS15 The Lean Six Sigma Approach Define Scope / Opportunity Current State  Future State  Gap Process cleanup 5S and other Lean Tools Known Solution Lean Project 6 Sigma Project New Design? DMADV DMAIC Yes No YesNo