Slides 10 2 apply DMAIC (define, measure, analyze, improve,

Lean 6σ Department of Defense Lean Six Sigma Executive level overview There must be a better way! • • Agenda: Lean Six Sigma Overview – The foundation of LSS – Lean / Six Sigma / LSS – DMAIC Lean 6σ Terminal Learning Objective • • • Task: Apply DMAIC to a Simple Work Process Condition: You are training to become an ACE with access to ICAM course handouts, readings, and spreadsheet tools and awareness of Operational Environment (OE)/Contemporary Operational Environment (COE) variables and actors Standard: with at least 80% accuracy: – Describe the foundation of Lean and Six Sigma – Define the underlying theory of Six Sigma – Describe the principles of Lean Six Sigma – Explain the concepts of DMAIC Lean Six Sigma overview Lean 6σ • • • • • Why Lean Six Sigma Principles and Tools Deputy Chief of Staff Army G-1 www.armyg1.army.mil/leansixsigma/whatislss.asp Performance Excellence… A Lean Six Sigma World-Class Methodology Where to Start…Voice of the Customer Foundation to Lean Sigma • Definitions of Insanity: • AND Lean 6σ – Doing the same thing over and over and expecting a different outcome! – Using the same logic to get out of the trouble that got you there in the first place! Albert Einstein Foundation to Lean Sigma Lean 6σ • • • "To measure is to know.“ "If you can not measure it, you can not improve it.“ "…I often say that when you can measure what you are speaking about, and express it in numbers, you know something about it; but when you cannot measure it, when you cannot express it in numbers, your knowledge is of a meager and unsatisfactory kind ” Lord Kelvin Right Training Right Attitude Lean 6σ • • • Lean Six Sigma is not rocket science…you can this Lean Six Sigma is not “easy”…it requires dedication and effort Lean Six Sigma is not the next program…it is a way of thinking…an approach to every task performed, that asks the question…“does this add value?” What is Lean? Lean 6σ • • • • • • Identifying improvement opportunities in processes Utilizes scientific problem solving methods Focus on reducing non-value added steps in a process Analyzing and improving process flows Reducing complexity Solving many smaller problems Value-Added Activities Lean 6σ The Lean Ladder Lean 6σ Identify and control the X’s Process output is A function of • • Y = f(X1,X2,…) • In Design • In Process Management Key process and input factors that cause variation in the output In Improvement – Identify the key X’s to reduce variation in the Y – Carefully set specifications on the X’s so that we get the desired Y – Monitor and control the X’s to assure we will get the desired Y Lean 6σ Why Aim as High as Sigma? Lean 6σ Lean The Look of 6σ Performance 6σ 3σ - 99% not defective 6σ – 99.99966% not defective Lost articles of mail per hour 20,000 Incorrect surgeries per wk 5,000 1.7 Wrong prescriptions each yr 200,000 68 Hours without electricity hr hr per month per 34 years Culture of Performance Improvement Lean 6σ Learning Check Lean 6σ • • • Why combine Lean manufacturing with Six Sigma? Why aim for 6σ? How you improve a sigma level? Overview of DMAIC Lean 6σ The DMAIC Process • • • • • • Provides a structured approach for addressing problems Provides a common language Minimizes the risk of jumping to the wrong conclusion Provides a checklist to prevent skipping steps Each step has goals, tools and outputs Tollgate reviews occur at each phase Lean 6σ Define • Goal Lean 6σ – Define project purpose and scope and obtain background information on the process and its customers • Outputs • Approach – Cleat statement of the intended problem and how to measure it – High-level process map – Key quality characteristics – Develop project charter – Map the process – Understand the voice of the customer Measure • Goal • Outputs • Approach – Focus the improvement effort by gathering information about the current situation – Baseline performance data – Common understanding of how the process currently operates – More focused problem statement – Collect data and check special causes – Create detailed process maps Lean 6σ Analyze • Goal • Outputs • Approach – Identify root cause and confirm with data – A tested and confirmed theory – Understanding of the effects of the inputs on the output – Explore and organize potential causes – Use statistical methods to quantify a cause-and-effect relationship Lean 6σ Improve • Goal • Outputs • Approach – Develop, try out and implement solutions – Planned and tested actions that eliminate or reduce the impact of root causes – Comparison of “before” and “after” data to show effects – Create possible solutions – Select solutions and develop plans – Implement plans and measure results Lean 6σ Control • Goal • Outputs • Approach – Maintain the gains by standardizing work methods or processes – Documentation of new methods – Train others in the new process – System for monitoring the new process – Develop and document standard practices – Train teams and monitor performance – Create process for updating procedures – Summarize and communicate learning Lean 6σ Learning Check Lean 6σ • • What does DMAIC stand for? Describe the DMAIC process? Lean Six Sigma Simulation • • • • • Lean 6σ Score for your team First round will use standard MRP batching process as defined by the instructor Second round implement the changes suggested by the class using DMAIC Each round will last 15 minutes The team with the most point WINS!! Questions? The Army OBT has more information on LSS and training opportunities www.armyg1.army.mil/leansixsigma/whatislss.asp Do you have any questions? Thank you for joining our discussion today Lean 6σ ... Sigma Overview – The foundation of LSS – Lean / Six Sigma / LSS – DMAIC Lean 6σ Terminal Learning Objective • • • Task: Apply DMAIC to a Simple Work Process Condition: You are training to become... 6σ – 99.99966% not defective Lost articles of mail per hour 20 ,000 Incorrect surgeries per wk 5,000 1.7 Wrong prescriptions each yr 20 0,000 68 Hours without electricity hr hr per month per 34... Result Reason Lean 6σ Identify and control the X’s Process output is A function of • • Y = f(X1,X2,…) • In Design • In Process Management Key process and input factors that cause variation in the