overview of lean six sigma simplified - qi macros of lean six sigma simplified jay arthur (888) 468...

Overview of

Lean Six Sigma Simplified

Jay Arthur (888) 468-1537

[email protected] © 2006 Jay Arthur (888) 468-1537

Overview

SIX SIGMA - Eliminate Defects Focus Improve Sustain Honor

LEAN - Eliminate Delay and Waste

Non-value added Types of Waste The Five S’s Pull Systems


Jargon Map

PDCA • Plan

DMAIC • Define • Measure

FISH • Focus

• Check • Act

• Control • Sustain • Honor

• Do • Analyze • Improve

• Improve

TQM Six Sigma Six Sigma Simplified


Focus (Define and Measure) Focus your efforts in ways that achieve breakthrough improvements in speed, quality and cost.

Tools Voice of the Customer Matrix – to

summarize what the customer wants in their own words.

Balanced Scorecard or Tree Diagram that links and aligns key measures to improvement efforts.


Improve (Analyze and Improve) Use data to identify and eliminate root causes of problems involving time, defects and cost. 4% of your business causes 50% of the waste and rework. (the 80/20 rule squared).

Tools Line Graph – Show errors and defects over

time. Pareto Chart – Look at errors by various

categories to identify the 20% of errors that cause 80% of the delay, defects and cost.

Ishikawa or Fishbone Diagram – Systematically analyze the root causes of problems. Ask why? Why? Why?


Sustain (Control) Use the tools of Statistical Process Control (SPC) to evaluate the ability of any business process to predictably and consistently meet customer requirements.

Tools Control Charts – Analyze your data to

determine process stability. Is your process consistent and predictable? Identify and research unstable points and conditions.

Histograms– Determine the distribution of measurable data and the capability of your process to meet customer requirements.

Flowcharts – Show the improved process including all activities, decisions and measurement points.

XBar Chart Title

UCL=0.819

CL=0.716

LCL=0.613

0.61

0.66

0.71

0.76

0.81

0.86

6/8

8am

10am

12pm 2pm

6/9

8am

10am

12pm 2pm

6/10

8am

10am

12pm 2pm

6/11

8am

10am

12pm 2pm

6/12

8am

10am

12pm 2pm

6/15

8am

10am

12pm 2pm

6/16

8am

Date/Time/Period/Number

Num

ber

XAverage

UCL

A

B

Average

B

A

LCL

Histogram

0

5

10

15

20

25

-24 to -18 -18 to -12 -12 to -6 -6 to 0 0 to 6 6 to 12 12 to 18 18 to 24 24 to 30

Values

Nu

mb

er

n= 4 8LSL= - 2 4

USL= 2 4

Cp( sigm a) = 1 .0

Cpk( sigm a) = 1 .0

Cp( Rd2 ) = 1 .2

Cpk( Rd2 ) = 1 .2

Pp= 1 .0

Ppk= 1 .0

Sigm a= 8 .0

Mean= 0

Median= 0


Design for Six Sigma (DFSS) To design products and services to be delivered, from the start, with Six Sigma Quality.

Tools

QFD House of Quality – Translate customer needs into your product and production process.

Failure Modes and Effects Analysis (FMEA)– Identity and Prevent Disaster.

Design of Experiments (DOE) – Fine tune your production process.


Lean Most Six Sigma efforts are incorporating the principles of Lean Manufacturing or the Toyota Production System. Therefore Six Sigma is now called Lean Six Sigma.

Determine and Create Value – value added flow analysis Use “pull” instead of “push” systems One Piece Flow – smaller batches Eliminate Waste Using the Five S’s

Sort, Straighten, Shine, Standardize and Sustain Types of Waste Include: Over Production, Excess Inventory,

Waiting, Unnecessary Movement of Work Products and Employees, Unnecessary or Incorrect Processing and Defects


Lean and Six Sigma Work Together

Value

Added

Defects TYPICAL

COMPANY

SIX SIGMA

LEAD TIME

LEAN and

SIX SIGMA NVA

TIME

Delay

Non-Value Added

Value

Added

Defects

Delay Non-Value Added

Value

Added


Implementing Lean Six Sigma The Seven Deadly Mistakes:

Committing to widespread implementation

Focus on training and teams, not results

Wide focus, not laser focus

Training Black Belts to train everyone else

Classroom training, not JIT training

Improvement teams, not SWAT teams

Letting teams pick their own problems


QI Macros SPC Software

The QI Macros is a series of Microsoft ® Excel add-ins and templates. It has three parts:

20 Macros to Create Charts – Just select your data and then select the chart from the QI Macros pull down menu on your Excel toolbar. Charts include pareto, scatter and control charts, histograms and box and whisker charts.

60 + Fill In the Blank Templates – In addition to templates for most of the above charts, there are templates to help you document your improvement stories including Voice of the Customer, Balanced Scorecard, Flowcharts, Ishikawa/ fishbone diagrams and much more.

Anova and Analysis Tools – An easy to use front end into Excel’s data analysis toolpak.


Free Resources and Contact Info

Jay Arthur KnowWare® International 2696 S. Colorado Blvd., Suite 555Denver, CO 80222 (888) 468-1537 [email protected] www.qimacros.com

30 Day Eval Copy of the QI Macros: www.qimacros.com/trial/30-day/ Six Sigma Quick Reference Card: qimacros.com/JobAid.pdf Lean Quick Reference Card - qimacros.com/pdf/leanaid.pdf SPC Quick Reference Card - qimacros.com/sustainaid.pdf

overview of lean six sigma simplified - qi macros of lean six sigma simplified jay arthur (888) 468...

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