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Sustaining Lean Six Sigma to Maintain Cost Savings and Profitability

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Tom Landry, Former Dallas Cowboys Head Coach: 'Rob is a coach's kind of guy, he never quits. ... himself with crutches over 24 miles from Fort Worth to Dallas! ... – PowerPoint PPT presentation

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Title: Sustaining Lean Six Sigma to Maintain Cost Savings and Profitability


1
Sustaining 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

2
Making 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

3
Making 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

4
My 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.
5
The 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.
6
Taking 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

7
LEAN 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)

8
Measuring the results using Lean Six Sigma
Apply Lean first, then Six Sigma.
9
How CSC Put Lean/Six Sigma in Place Against
Resistance
10
The 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
11
The 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.
12
The 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!
13
The 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.
14
The 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.
15
The 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
16
Message 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
17
Which 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.
18
Three 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

19
Five 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

20
How They All Fit TogetherMethodology Analogy
Solving Problems with Lean/Six Sigma
Lean/ Six Sigma
Six Sigma
Lean
Design for Six Sigma
Kaizen
21
Current 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.
22
Backup SlidesAbout the Speaker
23
Walking Through Adversity, Author Rob Bryant,
Published by HCI
24
A 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.

25
A 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.

26
Business 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

27
Personal 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

28
Experience. Results.
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