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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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