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Introduction to Lean Six Sigma - ADDVALUE - Nilesh Arora

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Know the history of lean six sigma by Nilesh Arora, a founder of AddValue Consulting Inc. He explained What is six sigma and how six sigma process follows? – PowerPoint PPT presentation

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Title: Introduction to Lean Six Sigma - ADDVALUE - Nilesh Arora


1
Six Sigma (6s)
by
Best Performing Consulting Organization
Adding Value In Totality !!
2
History of Six Sigma (6s)
  • In 1986 Bill smith, Seniors Engineer and
    scientist introduces concept of Six Sigma
  • Bill smith Known as Father of Six Sigma
  • In 1995, Jack Welch introduced Six Sigma at GE

3
Whats in a name?
  • Sigma is the Greek letter representing the
    standard deviation of a population of data.
  • Sigma is a measureof variation
  • (the data spread)

s
µ
4
What is Six Sigma ? A metric?
What is Six Sigma? A managemen
t system?
A philosophy?
A methodology?
5
What is Lean Six Sigma?
What is Lean ?
  • Goal Eliminate waste and increase process
    speed
  • Method
  • Genchi Genbutsu Go and See the workplace (Gemba)
  • Kaizen (Change for better) workshops

6
What is Lean Six Sigma ?
What is Six Sigma ?
  • Goal Reduce variation to improve performance on
    CTQs
  • (Variation means system does not produce same
    result each time)
  • Method DMAIC, DMADV,DFSS approach

7
Normal Distribution Curve
Lower Spec
Upper Spec
?
?

µ
-
- 1s
1s
68.26
- 2s
2s
95.44 99.73 99.9937 99.99943
3s
- 3s
4s
- 4s
5s
- 5s
6s
- 6s
99.999998
8
Sigma Good Bad DPMO
1 30.9 69.1 691,462
2 69.1 30.9 308,538
3 93.3 6.7 66,807
4 99.38 0.62 6,210
5 99.977 0.023 233
6 99.9997 0.00034 3.4
9
What is Six Sigma performance? Your process
is performing at sigma level of six if the
difference between mean and specification
limit is six times the standard deviation
USL Question - How many times of
standard deviation (s) is specification limit
to mean? Answer Same as sigma level for
the process (Z value)
LSL
Mean 1s
? times s
-6s
-5s -4s -3s -2s -1s
µ 1s
2s 3s 4s 5s 6s
10
Data Driven Approach
f (X)
Y
To get results, should we focus our behavior on
the Y or X ?

X1 . . . XN Independent Input Cause Problem Contro
l Factor

Y Dependent Output Effect Symptom Monitor Response
Is it feasible to eliminate the inspection of Y,
if Xs are controlled well?
11
How Six Sigma Process Follows?
  • Identify customer issues which generally follows
    timely delay, high cost, defect etc
  • Internalized as performance measures such as
  • e.g. Cycle time, defect rate etc.
  • Target performance levels are established and
    then company seek to perform around this targets
    with minimal variation

12
THE DMAIC METHOD
1
5
CONTROL
DEFINE
4
2
IMPROVE
MEASURE
3
ANALYZE
13
Projects Identification Method
Phase 1 Define
VOC ANALYSIS (Problem identification based on
customers voice)
List of problems/projects of organization on the
basis of Criticality, Out come , Time line
VOB ANALYSIS (Problem identification based on
Business problems)
Identification of CTQs
COPQ (Problem identification based on cost of
poor quality i.e. Process Defects )
14
Phase 2 Measure
  • Goal
  • Focus the improvement effort by gathering
    information on the current situation
  • Output
  • Data that pinpoints problem location or
    occurrence
  • Baseline data on current process sigma
  • A more focused problem statement

1
5
DEFINE
CONTROL
Baseline Data
4
2
Sampling
IMPROVE
MEASURE
Gage RR
3
Patterns
ANALYZE
Capability
15
DATA COLLECTION
  • The system to collect information is already
    established.
  • Find the data which supports the defined problem
  • Find out the data stream wise/ product wise etc..
  • Data type
  • Attribute data or Discreet Value of countable
    quality characteristics
  • Example - Number of Defects, Number of
    Defectives.
  • Continuous data or Variable data Value of
    measurable quality characteristics
  • Examples - Strength (kg/cm2), weight (kg)
    , length (cm), temperature ( C), time (sec)

16
Phase 3 Analyze
  • Goal
  • Identify deep root causes and confirm them with
    data
  • Output
  • A theory that has been tested and confirmed

1
5
DEFINE
CONTROL
4
2
IMPROVE
MEASURE
3
ANALYZE
DoE
Process Analysis
Organize Causes
Multi-Vari
Regression
Hypothesis Testing
17
Phase 4 Improve
  • Goal
  • Develop, pilot, and implement solutions that
    address root causes.
  • Output
  • Identification of planned, tested actions that
    should eliminate or reduce the impact of the
    identified root causes

1
5
CONTROL
DEFINE
Solutions
4
2
IMPROVE
MEASURE
FMEA
3
Pilot
ANALYZE
Implemen- tation
18
Solutions
  • Improvement team created with members of Quality,
    Production, Engineering and RD areas to propose
    and evaluate ideas.
  • Brainstorming tool was used to gather ideas on
    how to solve the problems identified.
  • Ideas were evaluated per following criteria
    feasible, high impact, easy, low cost, and quick.
  • Following tables summarizes solutions agreed by
    consensus of the improvement team.

19
Phase 5 Control
Control
Standardize
  • Goal
  • Use data to evaluate both the solutions and the
    plans
  • Validate that all changes adhere to all operating
    company change control, and compliance
    requirements
  • Maintain the gains by standardizing processes
  • Outline next steps for on-going improvement
  • Output
  • Before-and-After analysis
  • Monitoring system
  • Completed documentation of results, learning, and
    recommendations

Document
Evaluate
Monitor
1
5
Closure
CONTROL
DEFINE
4
2
IMPROVE
MEASURE
3
ANALYZE
20
Q.C STORY BOARD
  • Q.C Story board is representation of all steps
    taken from identification to solution and
    reviewable of taken probable solutions
  • Clear problem identification is the most imp part
    of Q.C Story Board
  • Different dept people needs to be involved in a
    whole process to have fresh ideas

21
PARETO ANALYSIS
  • Known as 80-20 Rule
  • Used for identification of Major problems
  • To find out 20 problems which causes 80
    rejection

22
PARETO ANALYSIS
Percentage
Code of defect
23
FISHBONE DIAGRAM
24
5 WHY ANALYSIS
25
5 WHY ANALYSIS
26
(No Transcript)
27
ADDVALUE Services
VALUE ADDED COACHING-VAC
BUSINESS COACHING
LIFE COACHING
Operation Excellence
Counselling
Team Excellence
Therapy
Adding Value In Totality !!
Business Excellence
Astrology
28
AddValue at a glance
Best Performing Consulting Organization
Business Coaching
Life Coaching
29
Thank You
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