Lecture 1: introduction to Lean Sigma, Six Sigma Flashcards
Definition of Lean
an approach to emphasises the smooth flow of items synchronised to demand to identify waste
Definition of Six Sigma
A disciplined methodology of improving every product, process, and transaction
What happens when you combine and apply lean and Six Sigma in the company level
It will result in companies improvement. All these improvement approaches share overlapping sets of elements
What is Six Sigma about
improvement of products/ services in terms of quality it leads to reduction of defects, defective products/ variations
What does lean do?
It helps company to be efficient and reduces cost
Why is lean six sigma effective and efficient?
It is effective because it reduces variation and reduces defects
It is efficient because it reduces waste, and value added-steps
What are the five key principles of lean?
- Define value add and non-value add
- Map the value stream
- Establish process flow
- Shift from push to pull systems
- Strive for perfection/ zero defects
What is Six Sigma
It is an organizational philosophy, a methodology, a standard deviation of population, and a process capability metric
What is the goal of Six Sigma
To reduce variation related to the variation within process output (Y) caused by input or process variables. To reduce variation towards customer target and specifications, To reduce variation by eliminating waste
What are the key benefits when applying Six Sigma
high customer satisfaction, high employee satisfaction, and increase in shareholders value
How can customer satisfaction be achieved
- Conformance to specifications (crosby)
- Value
- Fitness for use (juran)
- support
- Psychological impressions
What are the steps to monitor progress: DMAIC? (5)
- Define-the opportunity from both business and customer perspectives
- Measure -Understand the process and its performance
- analyze- search for the key factors that have the biggest impact on process performance
- improve -Develop improvement solutions for the critical X’s
5 control- Implement the solution and control plan
What is the Six Sigma methodology
Define, Measure, Analyze, Improve and control.
It is used to improve existing processes
Define stage DMAIC
describe the problem we are working and the CTQ organize the team -> get to know the problem
Measure stage DMAIC
define the defect. Choose Y, describe process, collect data with capable measurement system, establish baseline process capability and establish improvement goals (to know how big the problem is)
Analyze stage DMAIC
determine which process inputs most influence the key process outputs (identify the root causes, understanding the gap)
Improve stage DMAIC
identify routes to improving performance& confirm changes will achieve the project goals (find solution to address the root causes in the identify phase)
Control stage DMAIC
implement the solution and establish an ongoing mechanism to “lock-in” the improvement and to share them elsewhere (implement the solutions and measure the success by the use of control tools
Different lean six sigma certifications
IASSC certification
ASQ
Lean Six Sigma roles (5)
Yellow belts Green belts Black belts Project sponsor Deployment manager
Lean Six sigma roles; yellow belts
awareness level
participation in project part-time in the function
Lean Six sigma roles; green belts
certified level of competency
lead projects part-time in their function
responsible for majority of projects and six sigma benefits
understands internal and external supply chains improvement needs
Lean Six sigma roles; black belts
Certified position/ demonstrated performers
Lead projects full time in their function
Dedicated to lead projects & train and coach green belts
Can define and improve supply chains using lean six sigma techniques
Lean Six sigma roles; project sponsor
identify opportunities, initiate & define projects
Creates an environment for GB/ BB to complete projects
Decision-maker during tollgate review
Lean Six sigma roles; deployment manager
lead project prioritization manage black belts track financial returns track certification of black belts and green belts create environment of knowledge sharing
Different ways to express process quality
DPMO
Yield %
CpK
σ, level
DPMO
defect per million opportunities
Yield
number of good products relative to the number of produced products. Chance of producing a unit with no defects/ errors
CpK
process capability relative to products specifications
σ, level
statistical measure of a process ability to consumer requirements
What does Six Sigma imply?
it implies process thinking
X (input cause) -> Y (output effect)
In other words Y= f (X’s). also know as transfer function
Just-in-time (JIT)
A philosophy of manufacturing based on planned elimination of all waste and on continous improvement of productivity
Customer satisfaction can be achieved by
- Conformance to specification
- Value
- Fitness for use
- Support
- Psychological impressions
