Define Phase - PowerPoint Presentation

Slide1

Define Phase

Elements of WasteSlide2

Elements of Waste

2

7 Components of Waste

5S

Understanding Six Sigma

Selecting Projects

Elements of Waste

Six Sigma Fundamentals

Wrap Up & Action ItemsSlide3

Definition of Lean

3

“

Lean Enterprise is based on the premise that anywhere work is being done, waste is being generated.

The Lean Enterprise seeks to organize its processes to the optimum level, through the continual focus on the identification and elimination of waste.

”

-- Barbara WheatSlide4

Lean – History

4Slide5

Lean Six Sigma

Lean Six Sigma combines the strengths of each system:

5

Lean

Guiding principles based operating system

Relentless elimination of all waste

Creation of process flow and demand pullResource optimizationSimple and visual

Strength: EfficiencySix Sigma

Focus on voice of the customerData and fact based decision makingVariation reduction to near perfection levels

Analytical and statistical rigorStrength: Effectiveness

An Extremely Powerful Combination!Slide6

Project Requirements for Lean

Perhaps one of the most criminal employee performance issues in today

’

s organizations is generated not by a desire to cheat one

’

s employer but rather by a lack of regard to waste. In every work environment there are multiple opportunities for reducing the non-value added activities that have (over time) become an ingrained part of the standard operating procedure.

These non-value added activities have become so ingrained in our process that they are no longer recognized for what they are, WASTE.waste (

v.) Anything other than the minimum amount of time, material, people, space, energy, etc needed to add value to the product or service you are providing.

The Japanese word for waste is muda.

6

Get that stuff outta here!Slide7

Seven Components of Waste

Muda is classified into seven components:

Overproduction

Correction (defects)

InventoryMotionOverprocessingConveyance

WaitingSometimes additional forms of muda are added:Under use of talent

Lack of safety7

Being Lean means eliminating waste.Slide8

Overproduction

Overproduction

is producing more than the next step needs or more than the customer buys.

It may be the worst form of waste because it contributes to all the others.

8

Examples are:

Preparing extra reports

Reports not acted upon or even read

Multiple copies in data storageOver-ordering materials

Duplication of effort/reports

Waste of Overproduction relates to the excessive accumulation of work-in-process (WIP) or finished goods inventory.Slide9

Correction

Correction

of defects is as obvious as it sounds.

9

Examples are:

Incorrect data entry

Paying the wrong vendor

Misspelled words in communicationsMaking bad product

Materials or labor discarded during production

Eliminate errors!!

Waste of Correction includes the waste of handling and fixing mistakes. This is common in both manufacturing and transactional settings.Slide10

Inventory

Inventory

is the liability of materials that are bought, invested in and not immediately sold or used.

10

Examples are:

Transactions not processed

Bigger

“in box” than

“out box”Over-ordering materials consumed in-house

Over-ordering raw materials – just in case

Waste of Inventory is identical to overproduction except that it refers to the waste of acquiring raw material before the exact moment that it is needed.Slide11

Motion

Motion

is the unnecessary movement of people and equipment.

This includes looking for things like documents or parts as well as movement that is straining.

11

Examples are:

Extra stepsExtra data entry

Having to look for something

Waste of Motion examines how people move to ensure that value is added.Slide12

Overprocessing

Overprocessing

is tasks, activities and materials that don

’

t add value.

Can be caused by poor product or tool design as well as from not understanding what the customer wants.

12

Examples are:Sign-offs

Reports that contain more information than the customer wants or needsCommunications, reports, emails, contracts, etc that contain more than the necessary points (briefer is better)

Voice mails that are too long

Waste of Overprocessing relates to over-processing anything that may not be adding value in the eyes of the customer.Slide13

Conveyance

Conveyance

is

the unnecessary movement of material and goods.

Steps in a process should be located close to each other so movement is minimized.

13

Examples are:Extra steps in the process

Distance traveledMoving paper from place to place

Waste of Conveyance is the movement of material.Slide14

Waiting

Waiting

is nonproductive time due to lack of material, people, or equipment

.

Can be due to slow or broken machines, material not arriving on time, etc.

14

Examples are:

Processing once each month instead of as the work comes in

Showing up on time for a meeting that starts late Delayed work due to lack of communication from another internal group

Waste of Waiting is the cost of an idle resource.Slide15

Exercise

Exercise

objective:

To identify waste that occurs in your processes.

Write an example of each type of Muda below:

Overproduction

___________________Correction ___________________

Inventory ___________________

Motion ___________________Overprocessing

___________________Conveyance

___________________Waiting

___________________

15Slide16

5S – The Basics

5S is

a process designed to organize the workplace, keep it neat and clean, maintain standardized conditions and instill the discipline required to enable each individual to achieve and maintain a world class work environment.

Seiri - Put things in order

Seiton - Proper Arrangement

Seiso – Clean

Seiketsu – Purity

Shitsuke - Commitment16

5SSlide17

English Translation

There have been many attempts to force five English

“

S

”

words to maintain the original intent of 5S from Japanese. Listed below are typical English words used to translate: 1. Sort (Seiri)

2. Straighten or Systematically Arrange (Seiton)3. Shine or Spic and Span (Seiso)

4. Standardize (Seiketsu)5. Sustain or Self-Discipline (Shitsuke)

175 S

Sort

Identify necessary items and remove unnecessary ones, use time management.

Shine

Visual sweep of areas, eliminate dirt, dust and scrap. Make workplace shine.

Place things in such a way that they can be easily reached whenever they are needed.

Straighten

Make 5S strong in habit. Make problems appear and solve them.

Self-Discipline

Standardize

Work to standards, maintain standards, wear safety equipment.Slide18

Exercise

Exercise

objective:

To identify elements of 5S in your workplace.

Write an example for each of the 5S

’s below:

Sort

____________________Straighten ____________________

Shine ____________________

Standardize ____________________

Self-Discipline

____________________

18Slide19

Summary

At this point, you should be able to:

Identify and describe the 7 Elements of Waste

Describe 5S

Provide examples of how Lean Principles can affect your area

19Slide20

The Certified Lean Six Sigma Yellow Belt (CLSSYB) tests are useful for assessing a Yellow Belt

’

s knowledge of Lean Six Sigma. The CLSSYB can be used in preparation for the ASQ or IASSC Certified Six Sigma Yellow Belt exam or for any number of other certifications, including private company certifications.

The Certified Lean Six Sigma Yellow Belt Assessment

The Lean Six Sigma Yellow Belt Course Manual

Open Source Six Sigma Course Manuals are professionally designed and formatted manuals used by Belt

’s during training and for reference guides afterwards. The OSSS manuals complement the OSSS Training Materials and consist of slide content, instructional notes data sets

and templates.Get the latest products at…

www.OpenSourceSixSigma.com