7W and 6S Six Sigma Foundations - PowerPoint Presentation

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7W and 6S

Six Sigma Foundations Continuous Improvement Training

Six Sigma Simplicity

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Key Learning PointsThe Enemy – WasteThe Foundation – 6S

Six Sigma Simplicity

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Model for Six Sigma Performance

Six Sigma Tools and Process

Lean Tools and Process

6S and Waste Elimination

Empowered People

“

Continuous Improvement Mentality

”

Six Sigma Simplicity

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Objectives For Addressing WasteDefining wasteIdentifying sources of waste

Planning elimination of wasteEstablishing permanent controls to prevent the recurrence of waste

“MUDA”

Six Sigma Simplicity

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Overprocessing

Transportation

Inventory

Overproduction

Rework/Scrap/Defects

Waiting

Motion

Types of Waste

Formatting and Layout© 2000

Growtth

Consulting, Inc. All Rights Reserved

Six Sigma Simplicity

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Correcting or repairing a defect in materials or parts or correcting a processing error adds unnecessary costs because of additional equipment and/or labor expenses.

Rework / Scrap / DefectsSix Sigma Simplicity

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Producing more parts or work than are necessary.Producing parts or work at a faster rate than is required.

Overproduction

Six Sigma Simplicity

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Processing work which is unnecessary because it has no connection with advancing the line or improving the quality of the product

OverprocessingSix Sigma Simplicity

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Transportation is not something that directly contributes any added value to the product.

It is an incidental action. It must be avoided unless supplying items where and when they are needed.

Transportation

Six Sigma Simplicity

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Inventory is a drain on an organization’s overhead. The greater the inventory, the higher the overhead costs become

Excess inventory covers up: * Defective material in finished goods * Unacceptable changeover times * Excessive downtime * Process inefficiencies * Lack of urgency and priorities

Inventory

Six Sigma Simplicity

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Any movement of people or machinery which does not contribute added value to the product

Motion

Six Sigma Simplicity

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Idle time between operations or events

WaitingSix Sigma Simplicity

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Take 10 minutes to think about a particular process within your project and list one example of waste for each of the 7 types.

Be prepared to discuss as a group.Group ExerciseSix Sigma Simplicity

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6S Workplace Organization

Six Sigma Foundations Continuous Improvement TrainingSix Sigma Simplicity

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The Purpose of 6SImprove safetyIncrease qualityRemove waste from workplace

Provide reduction in non-VA activitiesCreate an environment for Continuous ImprovementSix Sigma Simplicity

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Six Sigma Simplicity

The 6S ActivitiesSort: Seiri (separate)

S

traighten:

Seiton

(put in order)

S

hine:

Seiso (shine, clean)

Standardize: Seiketsu (standards)

Safety: Anzensei (safety)Sustain: Shitsuke (discipline)

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Identify all items within the work area which are not required to perform the process.

Remove those items from the work area.

BEFORE

AFTER

Sort

Six Sigma Simplicity

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Any items identified “as required” must be assigned a specific location.

This location should be identified by outlining and/or labeling the item and its location.Straighten

Six Sigma Simplicity

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Shine

All dust, dirt, waste, etc. must be cleaned or not allowed to accumulate in order to set a new level of cleanliness and tidiness in the workplace. Cleanliness / tidiness not only provides a safe work area, it also highlights potential hazards.

Six Sigma Simplicity

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StandardizeThe ultimate workplace organizationResult of establishing acceptable standards for Sorting, Straighten and Shine

Clear and visual control of an acceptable level

Policy Statements

Visual Indicators

Location Maps

Continual emphasis upon

Sifting, Sorting, Sweeping

Six Sigma Simplicity

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Increased safety is a result of standardization:

Sort - The removal of unwanted items creates spaceStraighten - A place for everything ensures a safe location

Shine - Cleanliness not only provides a safe work area, it also highlights potential hazards

Safety

Six Sigma Simplicity

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SustainIndividual commitment to the maintenance of the 6S standards

The toughest “S” to achieve and maintain!

Active participation in setting improved standards

Monitor, Acknowledge & Feedback

Six Sigma Simplicity

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Typical Levels of AssessmentLevel E

Disorganized and dirtyParts and rubbish on floor and binsShelves cluttered with newspaper, lunch, obsolete stockLevel DNo debris in working areaWIP Organized

No obsolete stock; parts are labelled (including defects)

Level C

Aisles, equipment and materials are identified

Non-required tools and fixtures removed from workplace

Required tools and fixtures are identified and assigned a visible location

Level B

All small tools are identified and located for immediate access

6S standards are maintained with direction from supervision

Level A6S standards are maintained without supervisionOperators are searching for opportunities to improve

Six Sigma Simplicity

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Level E

Disarray:

What is required? What is not required?

Potential damage to WIP

Potentially hazardous to operator

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Level D

Some organization is apparent Cannot tell what is / is not required

Six Sigma Simplicity

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Level C

Organized and identified Obvious when missing

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Level B

Clean, neat, tidy Safe, no hidden dangers to worker or WIP Process problems obvious at a glance

Six Sigma Simplicity

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Level A

Standards are visible

Workers maintaining standards

Workers seeking out opportunities for improvement

Six Sigma Simplicity

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Take 10 minutes to think about a particular process within your project and list one example of where you could apply 6S workplace organization.

Be prepared to discuss as a group.Group Exercise

Six Sigma Simplicity

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7W and 6S

Six Sigma Foundations Continuous Improvement Training

Six Sigma Simplicity