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Six Sigma – A Strategy for Achieving World Class Performance

presented by:

Jonathan Blackman Matt Wilber Dianna Lewis Daniel Taylor

Quality-Six SigmaQuality-Six SigmaIntroduction to Quality

Six Sigma

Six Sigma Certification

Six Sigma – Lean Principles in Action

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Why is Quality Control Why is Quality Control Important?Important?

Defects Impact Bottom Line

Increases customer satisfaction

Safety

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Quality HistoryQuality History

Globalization of Industrial Capability

Japan Introduced Foundations of Quality

Quality Comes to America

Standardization of Methods

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Standardization of MethodsStandardization of Methods

Quality Assurance - Over the ShoulderTotal Quality Management – Empowered

the EmployeesSix Sigma – Current Standard

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Six SigmaSix Sigma

Process of asking questions that can produce tangible, quantifiable results

Employed by organizations to improve effectiveness through reducing defects

Goal is to reduce defects to the Six Sigma level (99.9997%) or 3.4 per M

Profit improvement through no rework

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Development of Six SigmaDevelopment of Six Sigma

Motorola formulated methodology 1986Developed for mfg.—modified for allCurrently integral to 100+ Fortune 500 Similar to predecessors…QC, TQM, ZDContinuous process involvement Requires top to bottom buy-in/support

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Organizational StructureOrganizational Structure

Executive Leadership: support/empowerChampions: implement resp. for co.Black Belt: in-house guidance/coachingGreen Belt: system improvement leaderEmployees: job experts integral in proc. DMAIC: Define, Measure, Analyze,Improve, Control…Process/Training

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DefineDefine

Create TeamProject PlanDefine ResourcesDefine ProblemCritical step…defines and clarifies

objective of the project

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MeasureMeasure

Map Current StateCollect DataProcess CapabilityDefine DefectsNeed to know the how and why of the

current state process

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AnalyzeAnalyze

Determine Process SpeedRoot Cause IdentificationPerformance ObjectivesValue Added/NonvalueHighlight areas for improvement, priority

list of problems/root causes…improve velocity while eliminating defects

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ImproveImprove

Develop SolutionsStraw ModelsCreate Action PlansValue Added/NonvalueImplementation of the best identified

solution(s) to the problem

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ControlControl

Develop Control PlanVerify BenefitsStatistical Process ControlDevelop Standards/ProceduresValidates and monitors the system

against standards/procedures to lock in gained benefits

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Benefits of Six SigmaBenefits of Six Sigma

Generates sustained successSets performance goal for everyoneEnhances value for customers;Accelerates rate of improvement;Promotes learning across boundaries;Executes strategic change

Six Sigma CertificationSix Sigma Certification

A confirmation that an individual has completed the necessary requirements from the company granting the certification.

Companies usually have their own criteria regarding testing and certification

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How to become certifiedHow to become certified

Learning the subject matter

Passing a written proficiency test

Display competency in a hands on environment

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Levels of certificationLevels of certification

White belt – works on local problem solving

Yellow belt – participates as a project team member

Green belt – assists in data collection for black belt projects

Black belt – leads problem solving projects

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Levels of certification (cont)Levels of certification (cont)

Master black belt – trains and coaches black and green belts, develops key metrics

Champions – translates the company’s vision, goals, and metrics

Executives – establishes the strategic focus of the six sigma program

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Why should I become Why should I become certified?certified?

Increased bottom lineIncreased customer satisfaction and loyaltyIncreases desirability from employers Higher starting levelHigher pay

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Tool Set for Manufacturing Tool Set for Manufacturing Efficiency OptimizationEfficiency Optimization

Integrated the Japanese principle of 5-S with the Six Sigma program to provide the complete tool set for manufacturing efficiency optimization

Why do Manufacturing and Administration Organizations use 5S?

5S is short for: Sort, Set in Order, Shine, Standardize and Sustain 5S represents 5 disciplines for maintaining a visual workplace.

Are foundational to continuous improvement

5S is one of the activities that will help ensure our company’s survival.

Some New WordsSome New Words

Red Tag-Process for tagging, removing and disposing of items not needed in the work area.

Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes

SomeSome 5S Examples 5S Examples

Before 5S

After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)

5S Examples - Sort, Set in 5S Examples - Sort, Set in OrderOrder

See the difference?

1. Sort - All unneeded tools, parts and supplies are removed from the area

2. Set in Order - A place for everything and everything is in its place

5S Examples - Shine5S Examples - Shine

3. Shine - The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean.

5S Examples - Standardize5S Examples - Standardize

4. Standardize - Cleaning and identification methods are consistently applied

Departments have weekly 5S tours

Every job has duties that use Sort, Set in Order and Shine

All have common duties to do our part to keep all areas of the work place in shape – break room, restrooms, locker area, parking lot, etc

5S Examples - Sustain5S Examples - Sustain

5. Sustain - 5S is a habit and is continually improved

5S is a simple concept with powerful results.

The better the work environment becomes: cleaner, safer, more organized, the work is easier, less confusion and less stress.

Use the 5S (work\home\play) - The more you use it the easier it becomes.

The Good, Bad and the UglyThe Good, Bad and the UglyFirst the Bad and the Ugly - Life Without 5S

The GoodThe Good

SummarySummary

5-S is for the work place.

Clean-up and organize your work area every day so that each new day is easier and safer than the day before

Share your input with your leaders so that the tools you need will be available to you, increasing your efficiency.

Volunteer to help with the 5S tours and 5S events.

Take a good look around...Imagine zero waste/zero confusion!

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