Introduction to Lean Six Sigma

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Introduction to Lean Six Sigma

description

Introduction to Lean Six Sigma. Learning Outline. What is Six Sigma The Six Sigma Philosophy Brief History of Six Sigma DMAIC Methodology Define Measure Analyze Improve Control . Why DMAIC is different from other Quality Models Six Sigma Certifications Six Sigma Roles - PowerPoint PPT Presentation

Transcript of Introduction to Lean Six Sigma

Page 1: Introduction to  Lean Six  Sigma

Introduction to Lean Six Sigma

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Learning Outline

• What is Six Sigma • The Six Sigma Philosophy • Brief History of Six Sigma • DMAIC Methodology

– Define – Measure – Analyze – Improve – Control

• Why DMAIC is different from other Quality Models

• Six Sigma Certifications• Six Sigma Roles • Recap

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What is Six Sigma (6σ)

Six Sigma (6σ) represents the level of quality when the defects are

decreased to 3.4 in 1,000,000 million opportunities

Few Examples Out of 1,000,000 parcels a courier company delivers apprx. 999,996 parcels on time while approx only 4 are delayed !

Out of 1,000,000 service hours a telecom company’s service are up 999,996 hours while experiencing the down time of only 4

hours!

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What is Six Sigma (6σ)

1,000,000 Opportunities

• Have you noticed the large sample size – i.e. 1,000,000 ? • What if we don’t have 1,000,000 samples / opportunities

…… well lets run few quick tests

25,000 Opportunities 150 Opportunities

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Six Sigma Philosophy The quality of the product /service depends on the

process used to develop that product/service

Six Sigma : Improves the underlying business process Is Customer focused Uses statistical tools

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Brief History of Six Sigma

In 1818 Johann Carl Gaussian introduces concept of Normal Distribution – the basis of Six Sigma

Bill Cohen – an engineer in Motorola coined the term Six Sigma for the firs time

Bill Smith in 1986 standardized the Six Sigma i.e. 1 Mil Opportunities

Motorola , Citibank , general Electric and Allied Signals were the early adapter of Six Sigma

Motorola reported $ 16 Billion savings due to Six Sigma Adoption

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DMAIC Methodology DMAIC is abbreviation of the 5 key steps required to

run Six Sigma projects

DMAIC

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Define Phase – Steps & Tools Define

Develop Charter and Business Case

SIPOC

Map Existing Processes

Process Mapping

Value Stream Mapping

Spaghetti Chart

Collect Voice of Customer

VOC

Affinity Diagram

Specify CTQ Requirements

CTQ Tree

Step Tools

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Measure Phase – Steps & Tools Measure

Measure CTQs

CTQ Tree

Determine Process Stability

Statistical Process Control

Data & Data Collection

Data collection Check Sheet

Validate Measurement System

R& R gauge

Establish Process Capability

Calculating Cp & Cpk

Histogram

Step Tools

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Analyze Phase – Steps & Tools Analyze

Identify Root Causes

5-Whys

Fishbone Diagram

Quantify Root Causes

FMEA Tools

Verify Root Causes

Scatter Plot

Correlation and Regressions Analysis

Step Tools

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Improve Phase – Steps & Tools Improve

Generate and Select Solutions

Brainstorming

Deign Solutions

Cost-Benefit Analysis

ROI

Prioritize and Select Solutions

Pilot Solutions

Implementing Solutions

A3 Report

Step Tools

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Control Phase – Steps & Tools Develop Control

Develop Control Plan

Apply Statistical Process Control

Transfer Required Tools to Process Owners

Perform Financial Evaluation and Audit

Step Tools

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How is DMAIC Different

DMAIC

Comprehensive

Project Based

Cohesive Process BasedQuantitative

Stakeholder improvement

Customer Centric

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Six Sigma Certification MASTER BLACK BELT

BLACK BELT

GREEN BELT

YELLOW BELT

WHITE BELT

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Six Sigma Roles Executive Management / Sponsors

MASTER BLACK BELT

BLACK BELT

GREEN BELT

YELLOW BELT

WHITE BELT

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RecapSix Sigma :

Improves the underlying business process Is Customer focused Uses statistical tools

DMAIC is Six Sigma Methodology with following phases : Define Measure Analyze Improve Control

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Thank you for attending this e-learning module.For any questions , queries and help – join us on the

following Linkedin Group

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