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Core Concepts of Lean Six Sigma Agenda

Welcome

  • Introductions
  • Workshop Objectives & Agenda


Lean Six Sigma Fundamentals

  • Who Finds Value in Lean Six Sigma
  • A Brief History of Continuous Improvement

    • The premise of Lean
    • The Premise of Six Sigma
    • Lean Six Sigma - a powerful combination
  • Process Improvement Roles

    • Black Belt, Green Belt, Yellow Belt/White Belt, Master Black Belt
    • Project Champions, Executives, Process Owners
  • Core Elements of Lean Six Sigma

    • Understanding customer requirements
    • Streamlining flow/maximizing value
    • Controlling variation/eliminating defects
    • Continuously improving performance
  • Process Improvement Roles and Responsibilities

    • Leaders, Champions, Project Team Members - Black Belts, Green Belts, Yellow Belts/White Belts
  • Lean Six Sigma Improvement Examples

    ACTIVITY: What issues in the examples are issues in your organization?


Executing Improvement Projects

  • DMAIC Project Model

    • ACTIVITY: Simulation – "Six Sigma Station": Round
  • Define: Setting up the Project

    • Define roadmap & overview
    • Voice of the customer & requirements

      ACTIVITY:       Simulation – Identify customer requirements (collecting VOC).

    • Charter: Business case, problem and goal statements
    • COPQ (Cost of Poor Quality)

      ACTIVITY: Simulation – Develop a problem and goal statement.

    • SIPOC diagrams

      ACTIVITY: Simulation – Simulation – Create a SIPOC diagram.
    • Detailed process mapping

      ACTIVITY: Simulation – Simulation – Create a detailed process map.

    • Spaghetti Chart
    • Define checklist
  • Measure: Validating the Problem; Tracking the Process

    • Measure roadmap and overview
    • Inputs and Outputs ("Xs" and "Ys")
    • Operational definitions

      ACTIVITY: Simulation – Review feedback data, refine goals.

    • Measure checklist
  • Analyze: Understanding the Cause

    • Analyze roadmap and overview
    • Data display tools

      ACTIVITY: Simulation – Data display (Histogram and Pareto Chart).

    • Value Analysis

      ACTIVITY: Simulation – Analyze the “value” and determine the status of each step.

    • Cause & effect analysis / Five Whys

      ACTIVITY: Simulation – Identify root causes of inability to meet customers’ needs.
    • Analyze checklist
  • Improve: Developing and Implementing Solutions
    • Improve roadmap and overview
    • 5S and workplace organization

      ACTIVITY: Simulation – Simulation – "Six Sigma Station": Round 2.

    • Improve checklist
  • Control: Sustaining & Monitoring Solutions

    • Control roadmap & overview
    • Elements of a control plan
    • Control checklist
  • Redesign: When Improving A Process Isn't Enough

    • More precisely defining customer requirements
    • Types of waste
    • Cell design
    • Single piece flow
    • Eliminating batch processing
    • Customer pull and takt time
    • Visual Controls

      ACTIVITY: Simulation – Simulation – "Six Sigma Station": Round 3.


Moving Ahead

  • How Does The Simulation Compare to Real Life?
  • What Next Steps Can You Take?

    • Assess the efficiency and effectiveness of your business
    • Apply DMAIC to an existing or upcoming project
    • Evaluate and adjust your measurement system

 

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