http:// lean six sigma methodology
TRANSCRIPT
http://www.tefen.com/industries.asp?pageInstanceId=150
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
Waste in Operations
• Overproduction
• Waiting time
• Transporting
• Non-value added processing
• Inventory
• Defects
• Underutilized talent
Fig. 15.1, p. 686
Customer
Sales
Production control
Plant A
Warehouse
Plant B
Transport
Order Product
Process Order
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
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
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.
5 S Philosophy
• Seiri – Sort
• Seiton – Set in Order
• Seiso – Shine
• Seiketsu – Standardize
• Shitsuke – Sustain
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
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
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
Visible Kanban (Control)
1- Card Kanban2-Card Kanban
ProductionMove
Production Move
Visible Kanban
JIT Experiential Exercise
Kaizen – Continuous Improvement
DMAIC
Define
Measure
Analyze
Improve
Control
Kaizen – Continuous Improvement
PDSA
Plan
Do
Study
Act