“A Quality System Approach towards Organizational Excellence”

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Lean  Six  Sigma:    �  “Lean” means “without waste” �  The term Six Sigma originated from terminology associated with manufacturing,

specifically terms associated with statistical modeling of manufacturing processes. The maturity of a manufacturing process can be described by a sigma rating indicating its yield or the percentage of defect-free products it creates. A six sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defective parts/million), although this defect level corresponds to only a 4.5 sigma level. Motorola set a goal of "six sigma" for all of its manufacturing operations, and this goal became a by-word for the management and engineering practices used to achieve it.

�  Six Sigma is a set of techniques and tools for process improvement. It was developed by Motorola in 1986. Jack Welch made it central to his business strategy at General Electric in 1995. Today, it is used in many industrial sectors.

�  “Lean Six Sigma” means “Elimination of wastages from entire Business model by using six sigma methodology.”

QSB Quality System Basics

FOUNDATION 5S Key Matrices Visual Controls Dashboard Displays TPM Skill Matrix Deployment

1. Problem Known Cause Known -  Kaizen Blitz -  Control plans -  Poka Yoke -  Automation -  SMED -  CFM -  Just do it !

2. Problem Known Cause Un known -  Fishbone Diagrams -  DOE -  KTA -  Hypothesis Testing -  Regression Analysis

4. Problem Un known Unrecognized -  FMEA -  HACCP -  PPA -  TRIZ -  QFD -  DFSS

3. Problem Suspected But Un known -  SIPOC -  Process Mapping -  Value Stream Mapping -  Control Charts -  Capability Analysis  

Supporting  Tools      Gauge  R&R    Pareto  Analysis    Affinity  Diagram    Force  field  Analysis      Team  Chartering    Brain  Storming      VOC      RACI      

House  of  LEAN  Six  Sigma    

M A D VD

M A I   CD

I   C

M A I   CD

M A I   C

QSB Quality System Basics

Lean:     Lean is a process management philosophy derived mostly from the Toyota Production System (TPS). It is a powerful method that allows organizations to improve the productivity, efficiency, and quality of their products or services. Companies today, from a wide range of industries, government agencies and other areas are finding ways to apply the principles of lean as a means of producing goods and delivering services that creates value for the customer with the minimum amount of waste and the highest level of quality.

Lean manufacturing, Lean Enterprise, or lean production, often simply, "lean", considers the expenditure of resources in any aspect other than the direct creation of value for the end customer to be wasteful, and thus a target for elimination. Working from the perspective of the client who consumes a product or service, "value" is any action or process that a customer would be willing to pay for.

For many, lean is the set of "tools" that assist in the identification and steady elimination of waste (muda). As waste is eliminated quality improves while production time and cost are reduced. A non exhaustive list of such tools would include: SMED, Value Stream Mapping, Five S, Kanban (pull systems), poka-yoke (error-proofing), Total Productive Maintenance, elimination of time batching, mixed model processing, Rank Order Clustering, single point scheduling, redesigning working cells, multi- process handling and control charts (for checking mura).

QSB Quality System Basics

5S M

anag

emen

t • SERI

• SEITON

• SEISO

• SEIKETSU

• SHITSUKE

• KAIZEN Visu

aliz

atio

n • Shop floor Layout

• Visualization of 3 moving items- Physical goods, standardized work , Management Information – KPI’s

•  Color coding •  Andon System

•  Visual Controls

•  Identification of abnormal things

Elim

inat

e / R

educ

e N

VA’s

•  VSM •  OEE •  Layout •  Multi

machine manning

•  Line Balancing

•  Quick Change Over – SMED

•  Lead time reduction

•  Inventory Turn Over ratio

•  Human Error prevention

•  SPF •  Low cost

Automation

Tota

l Pro

duct

ive

Mai

nten

ance

•  Autonomous Maintenance (Jishu Hozon)

• Preventive Maintenance

• Spare parts management

• Break Down Management

• Predictive maintenance

•  Individual Improvement (Kobetsu Kaizen)

•  Quality Maintenance

•  Education and training

•  Safety, health & environment

•  Development Management

•  Office TPM

Qui

ck R

espo

nse

Team

•  Multi

skilling

•  Andon

System

•  Trouble

shooting

analysis

KA

NB

AN

•  Customer

order driven

production

scheduling

•  Pull system-

Make to order

•  JIT- Inventory

management

•  Multi skilling

q  How to integrate & implement Lean Practices?

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QSB Quality System Basics

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QSB Quality System Basics

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