Before we start working on a project for process improvement.
It is very important to create awareness.
I made this presentation to provide basic understanding of Lean and six sigma.
Usually audience used to be SME, process owner and Higher management people.
After this training ,audience gets a roadmap/ strategy for improvement and how I will help them to improve.
I take their inputs after training and than we start with VOC, VOB and identification of problems and this is how I prefer to start.
2. What is Lean six sigma
Its all about Process/Quality improvement
Process improvement by increasing performance and
by decreasing variation
Lean six sigma is a vehicle for strategic change (Only
for critical reasons)
This is a combination of two approaches Lean and six
sigma
3. Lean
Lean concentrate on customer values, waste
elimination
Traditional working style is Result oriented. This is
good but on long run it becomes a problem when we
only concentrate on result rather than process
Lean emphasis on process that is driven for value
added services to customers. Instead of only expected
result delivery to customers.
4. 7 wastes in a process (WORMPIT)
Waiting
Rework
Over-Processing
Inventory (More “In box” and less “Out box”)
Transportation (When work is distributed our locations)
Over-production (Output that is more than required)
Motion (Un-necessary movement of work)
We have to reduce theses wastes from our work as much as
possible (Practically zero waste is not possible)
5. Six sigma
Statistical approach for change
Here everything is data driven
A six sigma project allows max 3.4 defects/Million
units
Advantages of Six sigma:-
Defect reduction
Yield improvement
Improved customer satisfaction
Higher net income
6. Data driven approach
Y = f(X)
Y X
Dependent Independent
Output Input
Effect or problem Cause
Symptom Problem
Monitor Control
Response Factor
7. Data driven approach
Our problem is Y, so if we want improve Y than we
have to identify X and we have to work on X
Six sigma gives us method for this i.e. DMAIC and
DMADV
DMAIC: For existing system
DMADV: For new system
8. About Six sigma
We can use Six sigma in following three manners for
improvement or to solve any problem
As philosophy (Roadmap)
As Method
As set of tools
In this session, We will concentrate of philosophy and
methods only
9. DMAIC
Six sigma is based on DMAIC and DMADV
approach.
DMADV: For developing new products
DMAIC: For improving existing products
We will discuss DMAIC in this session
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
10. Define
Define to know “What is important”
Six sigma approaches should only be used if problem is
critical and improving that problem will increase our
benefits a lot.
Define phase will give answers of “how bad the
problem is?” and “Should we use six sigma approach?”
Define phase will provide a project charter
It will give a process overview map and scope of work
11. Define steps
First and main step is be specific and have patience
We have to indentify only the problems ,no
solutions, no analysis. Nothing else but just the
problem identification (Y)
Let’s divide Define phase work:-
1. Generate project ideas
2. Identify and select Y measures
3. Select one primary Y measure
4. Generate Project charter and SIPOC
12. 1. Generate project ideas
Get list of problems using:-
i. Voice of customer (VOC)
ii. Voice of business (VOB)
iii. Cost of poor quality (COPQ)
To get more clarification about the current status of
a process, Use balanced scorecard
Identify critical to quality (CTQ)
13. Balanced Scorecard
Balanced SC in used to “Set, track, achieve key
objectives and strategy”
There are 4 balanced SC that can be used:-
1) Financial SC
2) Customer SC
3) Internal business SC
4) Learning and growth SC
In simple words, SC is to see where are we
now/before/later
14. Select project Y measure
Till now we should have many CTQ (Y)
Prioritize them using prioritization matrix
prioritization matrix includes:-
1) Risk
2) Impact
3) Effort
Here we are prioritizing the problems
16. Business charter and SIPOC
These are the main deliverables of Define phase.
Everything will be now based on selected most critical
Y (That we got in previous steps)
These documents will mainly be used by higher
management and they have to sign/approve project
based on these docs (Specially business charter)
Based on these documents, It will be decided that
should we start deploying six sigma on this project or
not.
18. Lets talk about this before moving forward
Six sigma approach eliminates the pain available in the
business processes…but this treatment is costly and not all
the processes are eligible for this.
Define phase reveals that what the pain? Do we have to
work on that? Working on that pain is even worthy?
Measure phase tells that what is the pain area?… Our
average performance is far from target or the problem is
variation or both.
Off course analyze phase will find the root cause and than
the improvement…
19. Measure
Following are the steps of measure:-
1. Define Y (Elaborate)
2. Collect data for Y
3. Select a measurement system to evaluate Y
4. Validate measurement system
5. Calculate any of below to evaluate current
performance
o Sigma level
o Process capability indicates
20. Measure
Lesser the sigma level, lesser the performance of
process.
Sigma level is a measure for a layman.
Process capability indicates (Cp, Cpk)
Cp gives information about deviation from target
Cpk with Cp gives information about variation in
performance
21.
22. Analyze
Y = f(X) = X1 + X2 + X3 + ….
This is root cause analysis
Following are the steps :-
1. List all probable X’s (2 ways)
Qualitative screening
Process Map analytics
2. Identify critical X’s
3. Verify sufficiency of critical X’s for the project
23.
24.
25. Validate critical potential inputs
Two ways:-
1. Hypothesis test:- For a particular X, this test tool
gives us information as follows:-
Business problem -> Mathematical case ->
Mathematical inference -> Business inference ($)
2. Forecast/ Regression analysis:- It includes Scatter
plot , Co-relation and Regression
26. Verify sufficiency of critical X
If improving critical X’s will have capability to realize
the targeted improvement, then move to improve
phase
Else find more X’s or review the project charter again
27. Improve
Generate and evaluate alternative solutions
Select and Optimize best solution
Pilot ,Implement and validate solution
28. Generating alternative solution
Process Mapping
Based on cycle time and VA/NVA analysis
Benchmarking
Ideation technique We will talk more about this
Brainstorming
De Bono Six Thinking Hats
Probing
29. Process mapping
Select the problem area
Create map for that process
Find the pain area
Detailed map for pain area
Act of improvement, deletion, leveling etc.
This step is basically is part of Lean practices.
30. Benchmarking types:-
Strategic
Process
Competitive
Functional
Internal
External
International
Any of the above should be considered as baseline for
benchmarking
31. Brainstorming
Generate as many as possible ideas in short time
Have Literal as well as vertical thinking
Literal thinking - Indirect and creative approach. May be
not possible to achieve by traditional way.
Vertical thinking – Selective ,analytical and sequential
approach
Don’t criticize any idea and encourage inputs from all
team members. Its not necessary in this step to get all
sensible solutions.
32. De Bono six thinking hats
This is creative thinking technique
Main motive is : creative problem solving by avoiding
negativity and group arguments
This technique is based on human emotions
33. Six colors and Associated human
emotions with these colors
White : Neutral ,objective
Red : Emotional and intuitive
Black : Cautious and Careful
Yellow : Hope and Positive
Green : Creative and lateral thinking
Blue: Control and organized thinking
34. How to use it to get solutions
Wear each hat at different time to get many solutions
for a problem
Analyze all the solutions and pick the best one
solution
35. Probing
Considered as child’s method
Answer below questions and a easy and common
solution will come out:-
Why do we need this process step?
Who else could be doing this?
Can we combine some tasks?
Journalists uses this method to remove layers of
hidden information
36. Evaluating a solution
We can use any of the following methods for
evaluating solutions:-
Multi – Voting
FMEA – Failure mode and effect analysis
Pugh matrix
37. Final steps for solutions
Validate changes on small scale (Pilot)
Evaluate the negative and positive impacts
To get a idea of full scale implementation
Full scale implementation
38. Control
Implement control system for critical X’s
Document solution and benefits
Transfer to process owner
39. Implement control system for
critical X’s
To ensure that process stays in control after the
solution has implemented
To quickly detect the out of control state and
associated special causes
Actions for the special states
40. In simple words ,we observe response of new changed
process for different sets of data
Make a chart for all responses
Put Min and Max limit of expected data
Check special events (Out of bound)
Take actions for special events
41. Document solutions and project
handover
Document all the solutions and benefits
Handover the project to process owner
42. Thanks
Aim of this presentation is to get a basic understanding of
DMAIC approach
Hope we got basic understanding
If you have any questions, please ask …
Contact details:
er.viral.jain@gmail.com
in.linkedin.com/pub/viral-jain-lean-six-sigma/23/b24/b9a/
Thank you …