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An introduction to lean six sigma

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An introduction to lean six sigma

  1. 1. www.businessbeam.com An Introduction to Lean Six Sigma Business Beam (Pvt.) Limited
  2. 2. Too Many Buzzwords, Which One to Chose?  Lean  Six Sigma  5S  Kaizen  Poka-Yoke  and many more… 2 Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.
  3. 3. Which track will help you run Marathon in min. possible time? Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.3
  4. 4. Logical Improvement Steps Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.4  Lets remove hurdles first… This is Lean!!!
  5. 5. What is Lean? Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.5  Lean manufacturing or lean production, often simply “Lean”, is a production practice that targets for elimination of waste.  What is Waste?  Anything other than the minimum amount of equipment,materials, parts, space, and worker’s time which are absolutely necessary to add value to the product.  For example:  Defects  Overproduction  Waiting  Non-utilized resources  Transportation  Inventory  Extra processing
  6. 6. Results of Lean Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.6 COST QUALITY DELIVERY (CycleTime) Low Cost  Lower working capital  Less scrap and rework  Higher productivity High Quality  Receive feedback at more frequent intervals  Introduce design/ quality improvements at a more rapid rate Fast Response to Market  Shorter delivery time  Faster to market with new products  Improved market share
  7. 7. Related Terms Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.7  There are several related terms  Kaizen  6S  PokaYoke  Just InTime  TQM
  8. 8. Kaizen Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.8  Kaizen is the organized use of common sense to improve cost, quality, delivery, and responsiveness to customer needs.  Five components of Kaizen are:  Teamwork  Personal discipline  Improved morale  Quality circles  Suggestions for improvement
  9. 9. 6S (5S plus Safety) Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.9 Sort Set in Order SustainStandardizeShine
  10. 10. Poka Yoke Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.10  A poka-yoke device is any mechanism that either prevents a mistake from being made or makes the mistake obvious at a glance.  The goal of poka-yoke is both prevention and detection: “errors will not turn into defects if feedback and action take place at the error stage.”
  11. 11. Six Sigma Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.11  A Measure ofVariability  How much Data falls within Customers’ Requirements  3.4 Defect per Million Opportunities or  99.99996% of Data or Opportunities  Higher the Process Sigma  The more Outputs meet Customers’ Requirements or  The fewer the Defects.
  12. 12. Performing at Six Sigma Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.12 .00034% Defects (Products Unacceptable to Customer) Mean Variation Product or Service Output 99.99966% Products Acceptable to customer
  13. 13. Six Sigma Implementation Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.13 DEFINE MEASURE ANALYZE IMPROVE CONTROL DMAIC
  14. 14. 1. Define Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.14  Activities performed  Map Current State  Customers  Demand Rate  Processes  Suppliers  Storage Locations  Product Flow  Information Flow DEFINE
  15. 15. 2. Measure Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.15  Activities performed  Measure Inventory  Total LeadTime  Total CycleTime  Process Time  Cycle Efficiency MEASURE
  16. 16. How far would you drive without your gauges?
  17. 17. 3. Analyze Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.18  Activities performed:  IdentifyWaste  Over Producing  Inventory  Waiting  Motion  Transportation  Defects  Processing  Build Strategy  Build To Order  AssembleTo Order  Finish To Order  EngineerTo Order  Identify the Pacemaker  Identify Issues ANALYZE
  18. 18. 4. Improve Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.19  Activities performed  Kaizen  Map Future State  Demand  Create Flow from Pacemaker  Create Pull from Pacemaker  Calculate Inventory amounts  Safety Stock  Buffer Sizes IMPROVE
  19. 19. 5. Control Copyrights (c) 2004-2013 Business Beam (Pvt.) Limited.All rights reserved.20  Activities performed  Create metrics to maintain Future State  Continuously Improve CONTROL
  20. 20. www.businessbeam.com Thank You! contact@businessbeam.com

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