Lean Six Sigma - An Introduction
This PDF document helps us to understand the below.
1] What is Lean Six Sigma
2] Why Lean Six Sigma
3] Road Map to Certification -
- How ?
- When ?
4] Value of Six Sigma
5] Summary
Graham and Doddsville - Issue 1 - Winter 2006 (1).pdf
LEAN Six Sigma - An Introduction
1. o What is Lean Six Sigma…
o Why Lean Six Sigma…
o How we do…
o When to do
Journey Towards Operational Excellence…..
1
2. Lean Six Sigma is a Business Management Strategy …
Seeks to identify and remove the causes of defects and errors
Uses a set of management methods, including statistical
methods
Creates a high performing culture within the organization
Aims To Deliver Breakthrough Performance In Business Or Operational Measures Like
Customer Satisfaction Rating Score
Cost of executing a business process transaction
Billing and Cash Collection lead time
Yield (Productivity) of service operations or production
“When you are finished changing, you're finished.”
Benjamin Franklin
2
3. ...Features that clearly distinguish Lean Six Sigma from other quality methodology
Six Sigma Lean is a
Motorola has
reported over rigorous, data-driven, result
US$17 oriented approach to
billion in process improvement.
savings from
It helps in improving
Six Sigma as
of 2006 quality, efficiency & speed
in every aspect of business
1) Ability to distinguish the problems and symptoms
2) Structured approach to problem solving
3) Root cause analysis for permanent fixes
4) Leverage the tools, techniques and best practices for data analysis and
solution
1) Able to achieve growth through increased productivity
2) Achieve great customer satisfaction
3) Improves employee engagement & satisfaction
4) Creates an overall high performing culture within the organization
5) Gives a competitive edge in the market place
“It is not enough to do your best; you must know what to do, and
then do your best “ - Deming
Company Confidential 3
4. Defining Road map
Institutionalizing Yellow Belt
Training &
Lean Six Sigma Monitor Certification
Culture
Train
Black Belt
Organizational
Training & Consult Framework
Certification
Green Belt
Training &
Certification
Our objective is to create value proposition & business
outcomes through six sigma consulting… 4
5. 1
•Define Goals & objectives Lean/Six Sigma
•Discussions on current issues Program Rollout
Define
•Why Six Sigma ( benefits) Employee Training plan
Lean Six Sigma •Training & Certification criteria; Role definition Six Sigma/Lean
Strategy •Benefits Realization & Review Mechanism Training Calendar
•Establish communication plan and channels for rollout Employees/Stakeholder
notification
2
Lean, Six-sigma •Six Sigma Awareness & LEAN Lean/Six Sigma
awareness across the
Yellow Belt •Training duration - 1 day; 7 hours training & 1 hour
evaluation board
Yellow Belt Certification
Basic Training •Recommendation - 2 weeks/month; 5 Days/Week : 25
for ~500 employees in
& Certification Participants/Session)
India
3
•Define Annual Savings Target
•KRA's to employees for Lean/Six Sigma Goal setting
Organizational •Metrics capturing & Reporting
Framework •Core Six Sigma team identification to steer the Employee
initiative throughout the organization Communication
•Define framework for Quality projects identification
A journey of a thousand miles begins with a single step
5
6. 4
Lean, Six-sigma • Green Belt Training Green Belt Training
Green Belt • Training Duration - 4 days (Weekdays, or weekdays Participant Certification
+ weekends by continuous) Completed one Six
Training & • Recommendation - 2 trainings/month ; Sigma Project
Certification 15 Participants/Session; ~115 participants Green Belt Certification
5
Black Belt Participation
Lean, Six-sigma • Black Belt Training Certification
Black Belt • Training Duration - 8 days (Wednesday to Saturday - Completed One Six Sigma
2 weeks) Project
Training & • Recommendation - 1 training/month ; 10 Mentored two Six Sigma
Certification Participants/Session; ~50 participants Projects
Black Belt Certification
6
• Yearly Target Plan for Lean Six Sigma
Institutionalizing • Lean Principles well deployed – 5S, Value Stream Culture change
Mapping, Kaizen
Lean Six Sigma • Lean Six Sigma mentor and champions should be
Company-wide
Culture Implementation Plan
easily available during this phase to encourage and
guide new teams
A journey of a thousand miles begins with a single step
6
7. Organizational Frame
work Green Belt Certification
Yellow Belt Certification
Yellow Belt Certification
Define Lean Six Sigma Yellow Belt Certification
Strategy
Green Belt Certification Green Belt Certification Green Belt Certification
Green Belt Certification Green Belt Certification 5S, Kaizen, Value
Black Belt Certification
Stream mapping
5S, Kaizen, Value
Green Belt Certification Green Belt Certification Stream mapping
Black Belt Certification Black Belt Certification Black Belt Certification
Black Belt Certification
5S, Kaizen, Value 5S, Kaizen, Value
5S, Kaizen, Value Stream mapping Stream mapping 5S, Kaizen, Value
Stream mapping Stream mapping
A journey of a Thousand miles begins with a single step
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8. Target Audience
Type Pre-Requisite Training Approach Certification Criteria
(Minimum)
Instructor led Class
All employees Room Training
1) Attending the YB Training
Yellow Belt None including support
2) Scoring 75% + in the evaluation test
function Long term - Web
Based Training
Team Leaders, Group
1) Attending the GB Training
Leaders & Project
2) Scoring 75% + in the GB evaluation
Yellow Belt Managers Instructor led Class
Green Belt test
Certified Room Training
3) 1 Green Belt project completion with
(25% of the total
annual saving of $5,000.00 or above
work force)
1) Attending the BB Training
2) Scoring 75%+ in the BB evaluation
Project Managers
test
Green Belt Instructor led Class
Black Belt 3) 2 GB Projects completion with total
Certified (10% of the total Room Training
annual savings of $10,000 or above
work force)
4) Mentoring of 2 GB projects along with
their certification
A Journey of a Thousand miles begins with a single step
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9. Designing Six Sigma Framework
•Designing the Six Sigma Strategy and Road map aligned to Organization’s goals
& objectives
•Goal setting for Six Sigma Strategy
•Lean Six Sigma Initiative branding
•Mechanism to Track & Report Benefits Realization
Training & Certification
•Designing the Training Calendar for Lean Six Sigma as per the Organization’s
HR/Training guidelines
•Certification criteria that is aligned to Organization’s Six Sigma Strategy
•Evaluation Question Paper to include both theoretical and Scenario based
questions
Consultation & Mentoring
•Conduct work shops, Brain storming sessions to identify opportunities for Lean &
Six Sigma projects also best practice sharing
•Help the team with the DMAIC/DMADV documentation and tollgate approvals
•Mentoring 10 Green Belt Projects
•Tracking and Reporting Benefits
With Lean Six Sigma… Only results counts…
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10. Focus on Preliminary requirements while
embarking on Lean Six Sigma
Imperative to adopt the phase wise
roadmap for a systematic approach
Need to promote it as a way of life from
now onwards
Other early adopters of Six Sigma who achieved great success include Honeywell
International and General Electric.
By the late 1990s, about two-thirds of the Fortune 500 organizations had begun Six
Sigma initiatives with the aim of reducing costs and improving quality.
Let’s Begin The Journey Towards Operational
Excellence… 10