Title: Sustaining Lean Six Sigma to Maintain Cost Savings and Profitability
1Sustaining Lean Six Sigma to Maintain Cost
Savings and Profitability
- Rob Bryant, CSC Lean/Six Sigma Program Leader
Corporate Vice President of Quality - April 30, 2008
2Making it Stick
- The company has to have the desire to change
(baseball story) - Align the change with a strategic initiative
- Passionate Executive sponsorship
- An endorsed Project charter
- Knowledgeable and excited team
- Process ownership shared by the team and formal
owner - Provide an amnesty program
- Provide an effective award program
3Making it Stick
- Set realistic goals
- Apply Lean first
- Assemble a passionate team willing to visualize
the steps, count the cost, pay the price, and
never give up! - Flattering introduction of team members
- Develop a phased approach
- Integrate motivational messages into events
- Conduct follow-up meetings
- Share the results of projects and the entire
program
4My Own Walk Through Change
- The fall that took it all
- My three thoughts on the way down
- This is really going to hurt
- Did I kiss my family goodbye?
- I will survive
- Paralysis
- Surgeries
Hard times do not dictate the outcome you do.
5The Resistance to Change
- The best and worst day of my life (Dr. and Jon)
- The parallel bars Mike
- The risk of not having a plan Pop
The first step toward change is the hardest.
6Taking the First Step Toward Change
- Who moved that leg?
- The first step is the hardest the 30 hall
- The daddy book
- The miracle walk
- The row across America
- Dont give up until the change is in place
- You have to crawl beforeyou can walk, run, or fly
7LEAN your processes to measure productivity and
sustain your deployments. This will reduce
- Loops
- Non-value added approvals
- Bottlenecks
- Series steps
- Unnecessary complexity
- Non-value added steps
- Process time/cycle time
- Problem steps
- Set-up time
- Manual effort
- Rework
- Pushes (insert pulls)
8Measuring the results using Lean Six Sigma
Apply Lean first, then Six Sigma.
9How CSC Put Lean/Six Sigma in Place Against
Resistance
10The Beginning of Lean/Six Sigma at CSC
- Although many successful Lean/Six Sigma companies
start a program from the top down, some grow from
the ground up.
Heres our story
11The Beginning of Lean/Six Sigma at CSC
In 2000, word came that a few of our accounts out
there were improving customer satisfaction and
revenue while reducing costs and errors.
It was like a voice from the wilderness.
12The Beginning of Lean/Six Sigma at CSC
The Master asked how? Turns out they were using
some new fangled tools and they called it
Six Sigma
The Master said, I dont care what you call it,
do more of it!
13The Beginning of Lean/Six Sigma at CSC
So, in early 2001 those few accounts began
training others in the use of those new fangled
tools. The Master asked, If it worked over
there, will it work over here?
And it did!And the practice spread, and it was
good.
14The Beginning of Lean/Six Sigma at CSC
In early 2002 the Master asked a few of the
Karate disciples (an MBB and several BBs) to
train a whole division in Lean/Six Sigma.
And they multiplied
and did statistical analysis as well.
15The Beginning of Lean/Six Sigma at CSC
By late 2002, it was working so well the Master
said to all the divisions, We are now a
Lean/Six Sigma company.
Embrace this new practice as it is now ours!
And that led to
16Message from Michael W. Laphen
The Beginning of Lean/Six Sigma at CSC
- CSC 45 Years of Leadership in Quality
Initiatives - As a world-class company with a 45-year history
of leadership in quality initiatives, CSC is
constantly looking for ways to improve the
quality of our processes and sharpen our focus on
serving clients. The CSC Six Sigma Program is an
integral part of this effort and a testament to
CSCs commitment to building process improvement
into our client engagements. - No matter what the area of your work, the Six
Sigma methodology will help you document,
understand, and improve your processes thereby
ensuring better service to your clients, higher
return on investment, and improved morale among
team members. - I look forward to your ongoing involvement in
this important program, which will play a
critical role in CSCs continued success. Please
ensure wide and successful deployment of this
initiative in your respectivebusiness units.
Michael W. LaphenPresident and Chief Operating
OfficerComputer Sciences Corporation
17Which projects do you choose? Gain momentum by
aligning business problems and strategic
initiatives.
Strategic Initiatives 1. Reduce time to receive
parts from vendors. 2. Reduce the cost of bidding.
Rejects
Rework
Inspection Costs
Testing
Scrap
Warranty
Pricing andBilling Errors
Morale, Productivity,Turnover
Long CycleTimes
CustomerAllowances
Lost Sales
ExcessiveOvertime
Lost CustomerLoyalty
Time withDissatisfiedCustomers
ExcessInventory
Expediting Parts
Late Delivery
Late Product Introduction
RevenueLeakage
OverdueReceivables
Eng. Change Orders
Lean/Six Sigma attacks the entire iceberg
systmatically resulting in higher quality, lower
cost, timeliness, and improved customer
satisfaction.
18Three Components to a Successful Six Sigma
Deployment
- Support system
- Infrastructure for the project/belt selection and
training - Finance engagement
- Management support at all levels
- Belts
- Crisp process for identifying the right belts
(Green Belt,Black Belt, Master Black Belt) - Conducting training
- Projects
- Crisp process for project selection
- Work with CSC to pick projects benefiting them
and reducing costs - Matching the belts with the projects
- Improve processes by increasing customer/employee
satisfaction, revenue, and performance while
reducing costs, waste, and defects
19Five Phases of Six Sigma Deployment
- Decide
- Executive team says "yes" to deployment of a Six
Sigma program - Establish infrastructure, methodology, and tools
to be used - Prepare
- Establish infrastructure
- Executives on board
- Pilot effort take successes and use as
springboard for other areas - Launch
- Initial training
- Pilot projects
- Expand can take 1 to 2 years
- Share successes within corporation to get more
support - Evaluate infrastructure
- Expand training
- Cultural shift
- Sustain future
- Integrate, audit, measure, assess, review
20How They All Fit TogetherMethodology Analogy
Solving Problems with Lean/Six Sigma
Lean/ Six Sigma
Six Sigma
Lean
Design for Six Sigma
Kaizen
21Current Situation
- More than 200 Six Sigma Black Belt projects and
close to 1,000 Green Belt projects already
implemented - CSCs Lean/Six Sigma program has decreased costs,
reduced SLA payment, or increased revenue by over
150M in just six years (validated by CSC Finance)
GIS/FSG Lean/Six Sigma Program Savings
M Savings
Years
CSC has a strong Lean/Six Sigma internal program
in GIS and FSG.
22Backup SlidesAbout the Speaker
23Walking Through Adversity, Author Rob Bryant,
Published by HCI
24A Few Endorsements
- Former First Lady Barbara Bush I am so glad to
have this opportunity to send my warmest
greetings and congratulations to Rob and Wanice
Bryant. Rob's determination certainly is an
enormous inspiration. George joins me in sending
our very best wishes. - Governor Arnold Schwarzenegger, California
Congratulations on your accomplishment of a
cross country trip on a row-cycle. That was a
monumental achievement, and I wish to
congratulate you on both your mental and physical
endurance. I deeply admire what you have done! - Tom Landry, Former Dallas Cowboys Head Coach
Rob is a coachs kind of guy, he never quits.
Rob set two world records even though he is
paralyzed from the waist down. He is a man of
faith, and I am looking forward to walking with
him in heaven some day. (Quote from a network
program which Tom Landry hosted.) - Author and Speaker Zig Ziglar Rob Bryant is an
effective speaker! He had our staff laughing one
minute and crying the next. He is an
inspirational man who, by example as well as a
very effective presentation, is able to give
encouragement and hope to those who have the
privilege of listening to him. He will be a hit
with your group. Robs message is timely and
challenging one that you will long remember.
Rob has a champions heart and is an
encouragement and inspiration to us all. - Author and Aerobics Authority Kenneth H. Cooper,
M.D. "Rob, I am overwhelmed by your
accomplishment in the face of unbelievable
obstacles! You are worthy of the highest praise
for motivating millions of people to improve
their health and fitness.
25A Few Endorsements (Contd)
- Minister Joni Erickson Tada Rob believes that
we should never give up! God has given us the
ability to either accept our situation, or change
it. (Quote from a broadcast) - USA Todays Ben Brown The next time you moan
about 20 minutes on an exercise bike, think about
Rob Bryant, a 35-year old aerospace engineer, who
has just finished a four-month, 3,280 mile
workout on an oar-equipped tricycle ... Though
paralyzed from the waist down, he also pushed and
pulled himself with crutches over 24 miles from
Fort Worth to Dallas! - Former Senator Chuck Robb, Virginia Rob, it is
with great pleasure that I congratulate you for
holding two world records and am honored that I
could greet you at the finish line at the
Capitol. Congratulations to you and your family. - Former Governor William Donald Schaefer,
Maryland It is with great pleasure that I
congratulate you. This grueling journey, which
more than tripled the previous world record, is
an outstanding and inspirational achievement. I
hope you are as proud of your Maryland roots as
we are of you. - State Senator Roy Dyson, Maryland Mr. Speaker,
I rise today to pay tribute to Rob Bryant's
employer and to Rob Bryant. Rob Bryant has been
a paraplegic since 1982 when he fell 55 feet from
an oil rig. Despite his handicap, he has just
completed a courageous 3,280 mile Row Across
America. Mr. Speaker, it is both an honor and a
pleasure to salute Rob Bryant today. - Former Congressman Pete Geren, Texas Mr.
Speaker, strength and perseverance rolled into
town this week in the heart of Rob Bryant. He has
just completed a 3,280 mile journey from Los
Angeles to Washington, DC on a hand propelled row
cycle. Rob Bryant is an author and stands tall in
our eyes. He is truly an inspiration to all of
us. - Senator Kay Granger, Texas I commend you for
your past and future accomplishments, your
generosity, and for being the special person for
whom we all have the greatest respect and
admiration.
26Business Accomplishments
- CSC Corporate Vice President for Quality
- Assisted DynCorp in increasing revenue from 900M
to 2.1B in just four years as a direct report to
the President - Certified Six Sigma Master Black Belt Trainer
led over 100 teams and studies resulting in over
100M in savings/revenue/improvements for all
divisions of CSC - Malcolm Baldridge Sr., Examiner for the National
MB Award for the Dept. of Commerce assessing
quality for the President of the United States - Served on the President Bush Business Advisory
Council for two years - Served as an editor for a book called Quality for
Dummies and has written several published
articles/papers for journals such as Quality
Digest, Six Sigma Magazine, and others - Quality Certifications include ISO-90012000,
TQM, Process Management, ITIL, CMMI, Six Sigma
Master Black Belt, Business Excellence, and
Malcolm Baldridge
27Personal Accomplishments
- Published author of three non-fiction books and
negotiating with literary agent on two more (a
fiction thriller and fictional love stories) - HCI (known for the Chicken Soup for the Soul
series) has now released Bryants latest book,
Walking Through Adversity - Motivational speaker with lnternational Speakers
Bureau (RobBryant.com) has spoken to over 500
business and civic organizations, churches,
hospitals, universities, high schools, and many
other groups - Two world records longest walk by paraplegic
(24 miles) and rowing 3,280 miles on a row
machine (Guinness Book of World Records,
1992-2000) - Nominated for Texas Businessman of the Year by
the Texas Republican Committee - Nominated as a National Republican Committee
Honorary Chairman and attended a dinner with
President G.H. Bush in that capacity - Past President of LeTourneau Alumni Association
- LeTourneau University Instructor Principles of
Self Management Administration Theory and
Practice Strategic Management Ethics and
Entrepreneurship
28Experience. Results.