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http://www.tefen.com/industries.asp?pageInstanceId=150 Lean Six Sigma Methodology

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Page 1: Http:// Lean Six Sigma Methodology

http://www.tefen.com/industries.asp?pageInstanceId=150

Lean Six Sigma Methodology

Page 2: Http:// Lean Six Sigma Methodology

Attributes of Lean Producers - they

• use JIT to eliminate virtually all inventory• build systems to help employees produce a

perfect part every time• reduce space requirements• develop close relationships with suppliers• educate suppliers• eliminate all but value-added activities• develop the workforce• make jobs more challenging• reduce the number of job classes and build

worker flexibility

Page 3: Http:// Lean Six Sigma Methodology

Waste in Operations

• Overproduction

• Waiting time

• Transporting

• Non-value added processing

• Inventory

• Defects

• Underutilized talent

Fig. 15.1, p. 686

Page 4: Http:// Lean Six Sigma Methodology

Customer

Sales

Production control

Plant A

Warehouse

Plant B

Transport

Order Product

Process Order

Print

Extrude

Receive product

Wait

Move

Wait Wait Wait

Move

Ord

er

Ord

er

WIP

WIP

WIP W

IP

Prod

uct

Prod

uct

Prod

uct

12 days 1 day 1 day 1 day 1 day13 days 4 days 10 days 9 days

Time Function Map

Page 5: Http:// Lean Six Sigma Methodology

Shipping

Customer

Customer sales representative

take order

Prepress Department(Prepare printing plates

and negatives)

Printing Department

Collating Department

Gluing, binding, stapling, labeling

Polywrap Department

Purchasing(order inks, paper,

other supplies)

Vendors

Receiving

Warehousing(ink, paper, etc.)

Accounting

Information flowMaterial flow

Production Process Flow Diagram

Page 6: Http:// Lean Six Sigma Methodology

5 WhysExample

The Washington Monument is disintegrating.Why? Use of harsh chemicalsWhy? To clean pigeon poopWhy so many pigeons? They eat spiders and there are a lot of spiders at monumentWhy so many spiders? They eat gnats and lots of gnats at monumentWhy so many gnats? They are attracted to the light at dusk.Solution: Turn on the lights at a later time.

Page 7: Http:// Lean Six Sigma Methodology

5 S Philosophy

• Seiri – Sort

• Seiton – Set in Order

• Seiso – Shine

• Seiketsu – Standardize

• Shitsuke – Sustain

Page 8: Http:// Lean Six Sigma Methodology

Initial Setup Time

Separate setup into preparation, and actual setup, doing as much as possible while the

machine/process is running (save 30 minutes)

Move material closer and improve material handling (save 20 minutes)

Standardize and improve tooling

(save 15 minutes)

90 min

60 min

45 min

25 min

15 minUse one-touch system to

eliminate adjustments (save 10 minutes)

Training operators and standardizing work procedures (save 2

minutes)

Step 1

Step 2

Step 3

Step 4

Step 513 min

Step 4

Steps to Reduce Setup Time

Page 9: Http:// Lean Six Sigma Methodology

A

A A B B B C

JIT Small Lots

Large-Lot Approach

Time

A A B B B C

A A A B B B B B B C C

JIT produces same amount in same time if setup times are lowered

Small versus Large Lots

Small lots also increase flexibility to meet customer demands

Page 10: Http:// Lean Six Sigma Methodology

Waste Reduction (%)

82%

50%

50%

30%

30%

20%

40%

0% 20% 40% 60% 80% 100%

Work-in-Process Inventory

Raw Material Inventory

Lead Time

Space

Finished Goods Inventory

Scrap

Setup Time

JIT Reduced Wasteat Hewlett-Packard

Page 11: Http:// Lean Six Sigma Methodology

Visible Kanban (Control)

1- Card Kanban2-Card Kanban

ProductionMove

Production Move

Visible Kanban

Page 12: Http:// Lean Six Sigma Methodology

JIT Experiential Exercise

Page 13: Http:// Lean Six Sigma Methodology

Kaizen – Continuous Improvement

DMAIC

Define

Measure

Analyze

Improve

Control

Page 14: Http:// Lean Six Sigma Methodology

Kaizen – Continuous Improvement

PDSA

Plan

Do

Study

Act