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Lean Six Sigma Brett Ellis, Ph.D., P.E., C.S.S.B.B. IEEE Seminar Wells Conference Center University of Maine, Orono, Maine November 8, 2018

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Page 1: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Lean Six SigmaBrett Ellis PhD PE CSSBB

IEEE SeminarWells Conference Center

University of Maine Orono MaineNovember 8 2018

Brett D Ellis PhD PE CSSBBbull Assistant Professor Mechanical Engineering Technology University of Maine

bull BS in Mechanical Engineering ndash University of Houstonbull MS in Mechanical Engineering ndash NC State Universitybull PhD in Mechanical Engineering ndash Georgia Institute of Technologybull 21 years experience in Mechanical Engineering

ndash Primarily in materials and product development

bull 10 years experience at Southeastern Container Incndash Product Development Managerndash Commercialized numerous bottles preforms and finishes

ndash Reduced commercialization time from 15 years to as little as 21 daysndash Reduced mean bottle mass by ~7

Redesigned water bottlesLighter finishes (-13 g) Redesigned preforms (-07 g)

Lean Six Sigmabull Lean Manufacturing (LM) ndash a continuous improvement

methodology that seeks to understand value (ie what customers are willing to pay for) and eliminate wastes (iewhat customers are unwilling to pay for)

bull Six Sigma (6σ) ndash a continuous improvement methodology to reduce defects to extremely low levels

LEAN MANUFACTURING

ValueNon-Value Added (VNVA)

bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred

bull Non-Value Added Activity ndash Any activity that does not add value to the product or service

bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted

1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes

Defects ndash Non-conforming production

Overproduction ndash Producing too much

Transportation ndash Forklifts conveyors trucks

Waiting ndash Idle operators

Inventory ndash Parts WIP inventory supplies

Motion ndash Unnecessary motion eg walking

Processing ndash Burr removal reshaping inspection

DOTWIMP

7 Types of Muda (ie Wastes)

Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine

Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S

2 S3 S4 S5 S

5S

Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices

Chemical cabinet Before 5S Chemical cabinet After 5S

Continuous Flow Efficient amp Faster

Traditional BatchLayout

Continuous FlowLayout

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 2: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Brett D Ellis PhD PE CSSBBbull Assistant Professor Mechanical Engineering Technology University of Maine

bull BS in Mechanical Engineering ndash University of Houstonbull MS in Mechanical Engineering ndash NC State Universitybull PhD in Mechanical Engineering ndash Georgia Institute of Technologybull 21 years experience in Mechanical Engineering

ndash Primarily in materials and product development

bull 10 years experience at Southeastern Container Incndash Product Development Managerndash Commercialized numerous bottles preforms and finishes

ndash Reduced commercialization time from 15 years to as little as 21 daysndash Reduced mean bottle mass by ~7

Redesigned water bottlesLighter finishes (-13 g) Redesigned preforms (-07 g)

Lean Six Sigmabull Lean Manufacturing (LM) ndash a continuous improvement

methodology that seeks to understand value (ie what customers are willing to pay for) and eliminate wastes (iewhat customers are unwilling to pay for)

bull Six Sigma (6σ) ndash a continuous improvement methodology to reduce defects to extremely low levels

LEAN MANUFACTURING

ValueNon-Value Added (VNVA)

bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred

bull Non-Value Added Activity ndash Any activity that does not add value to the product or service

bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted

1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes

Defects ndash Non-conforming production

Overproduction ndash Producing too much

Transportation ndash Forklifts conveyors trucks

Waiting ndash Idle operators

Inventory ndash Parts WIP inventory supplies

Motion ndash Unnecessary motion eg walking

Processing ndash Burr removal reshaping inspection

DOTWIMP

7 Types of Muda (ie Wastes)

Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine

Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S

2 S3 S4 S5 S

5S

Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices

Chemical cabinet Before 5S Chemical cabinet After 5S

Continuous Flow Efficient amp Faster

Traditional BatchLayout

Continuous FlowLayout

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 3: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Lean Six Sigmabull Lean Manufacturing (LM) ndash a continuous improvement

methodology that seeks to understand value (ie what customers are willing to pay for) and eliminate wastes (iewhat customers are unwilling to pay for)

bull Six Sigma (6σ) ndash a continuous improvement methodology to reduce defects to extremely low levels

LEAN MANUFACTURING

ValueNon-Value Added (VNVA)

bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred

bull Non-Value Added Activity ndash Any activity that does not add value to the product or service

bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted

1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes

Defects ndash Non-conforming production

Overproduction ndash Producing too much

Transportation ndash Forklifts conveyors trucks

Waiting ndash Idle operators

Inventory ndash Parts WIP inventory supplies

Motion ndash Unnecessary motion eg walking

Processing ndash Burr removal reshaping inspection

DOTWIMP

7 Types of Muda (ie Wastes)

Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine

Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S

2 S3 S4 S5 S

5S

Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices

Chemical cabinet Before 5S Chemical cabinet After 5S

Continuous Flow Efficient amp Faster

Traditional BatchLayout

Continuous FlowLayout

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 4: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

LEAN MANUFACTURING

ValueNon-Value Added (VNVA)

bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred

bull Non-Value Added Activity ndash Any activity that does not add value to the product or service

bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted

1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes

Defects ndash Non-conforming production

Overproduction ndash Producing too much

Transportation ndash Forklifts conveyors trucks

Waiting ndash Idle operators

Inventory ndash Parts WIP inventory supplies

Motion ndash Unnecessary motion eg walking

Processing ndash Burr removal reshaping inspection

DOTWIMP

7 Types of Muda (ie Wastes)

Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine

Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S

2 S3 S4 S5 S

5S

Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices

Chemical cabinet Before 5S Chemical cabinet After 5S

Continuous Flow Efficient amp Faster

Traditional BatchLayout

Continuous FlowLayout

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 5: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

ValueNon-Value Added (VNVA)

bull Value Added Activity ndash Any activity the customer would be willing to pay for if they knew the process occurred

bull Non-Value Added Activity ndash Any activity that does not add value to the product or service

bull Most studies1 indicate that value is added lt 5 of the time gt95 of the time is wasted

1 httpleanmanufacturingtoolsorg89value-add-vs-non-value-adding-processes

Defects ndash Non-conforming production

Overproduction ndash Producing too much

Transportation ndash Forklifts conveyors trucks

Waiting ndash Idle operators

Inventory ndash Parts WIP inventory supplies

Motion ndash Unnecessary motion eg walking

Processing ndash Burr removal reshaping inspection

DOTWIMP

7 Types of Muda (ie Wastes)

Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine

Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S

2 S3 S4 S5 S

5S

Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices

Chemical cabinet Before 5S Chemical cabinet After 5S

Continuous Flow Efficient amp Faster

Traditional BatchLayout

Continuous FlowLayout

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 6: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Defects ndash Non-conforming production

Overproduction ndash Producing too much

Transportation ndash Forklifts conveyors trucks

Waiting ndash Idle operators

Inventory ndash Parts WIP inventory supplies

Motion ndash Unnecessary motion eg walking

Processing ndash Burr removal reshaping inspection

DOTWIMP

7 Types of Muda (ie Wastes)

Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine

Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S

2 S3 S4 S5 S

5S

Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices

Chemical cabinet Before 5S Chemical cabinet After 5S

Continuous Flow Efficient amp Faster

Traditional BatchLayout

Continuous FlowLayout

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 7: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Sustain ndash Commit to previous 4 stepsStandardize ndash Make cleaning amp checking routine

Scrub ndash Clean method to keep everything cleanStraighten ndash A place for everything everything in its placeSort ndash Eliminate all un-needed items major cleaning1 S

2 S3 S4 S5 S

5S

Source QCI (2014) CSSBB Primer p IX-38httpstotalqualitymanagementwordpresscom20100323some-images-of-5s-houskeeping-in-factories-and-offices

Chemical cabinet Before 5S Chemical cabinet After 5S

Continuous Flow Efficient amp Faster

Traditional BatchLayout

Continuous FlowLayout

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 8: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Continuous Flow Efficient amp Faster

Traditional BatchLayout

Continuous FlowLayout

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 9: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Poke-Yoke Mistake Proofing

Poke-Yoke ndash A mistake-proofing device or procedure to prevent or detect an errorSource httpwwwleanblogorg201103simple-brilliant-error-proofing-at-the-world-famous-in-n-out-burger

httpwwwmaderalabscomp=1241httpwwwainsmagcouknewsimagesab2374398ab1hjpgQCI (2014) CSSBB Primer p VI-3

In-N-Out Burger trays wonrsquot fit in

trash can

Diesel and gas nozzles

Collision between cars and trains

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 10: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Lean Manufacturing Example

Source httpcmuscmblogspotcom201401mcdonalds-secret-sauce-for-supply-chain_21htmlhttpsenwikipediaorgwikiKanbanQCI (2014) CSSBB Primer p VI-3

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 11: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

SIX SIGMA

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 12: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Six Sigma 6σbull Six Sigma is a methodology to reduce defects to very low

levels

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Prob

abili

ty

Standard deviation σ

x_

+6σ( )2

1

1

Nii

x xN

σ =minus

=minus

sum

1 Assuming 5 characters per word 300 words per page and 250 pages in a bookhttpwwwquoracomHow-many-characters-of-text-letters-are-in-an-average-book

bull A 6σ process produces ~34 Defects Per Million Opportunities (DPMO) ~13 incorrect characters in a 250-page book1

~1 defective Christmas light for ~500 houses2

Christmas lights

Not 6σ

2 Assuming 2000 lights per house Typical light user uses 1 to 3 wreaths garland and ~10 strings of lights httpwwwchristmaslightsetccompageshow-much-powerhtm

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 13: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Why is Six Sigma Importantbull Problem-solving approaches that employ only

theoretical equations have shortcomingsndash Rely upon highly-specialized skill sets to produce a solutionndash Not guaranteed to produce a unique solutionndash Focus on the mechanics of a problem What about other

factors eg operators measurement system atmospheric humidity interactions

ndash Theoretical approaches are typically deterministic whereas real-world systems respond stochastically

ndash Even if a useful solution can be obtained do other approaches produce a useful solution quicker or cheaper

bull Six Sigma addresses these shortcoming via a systematic empirical approach

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 14: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Why is Six Sigma Importantbull Motorola saved ~$16 billion in the first five years of

implementation

bull GE saved ~$12 billion in the first five years of implementation

bull Maine companies utilizing Lean Six Sigmandash Pratt amp Whitney GE Jackson Lab IDEXX Nichols Portland

LLC Owens Corning Ensign-Bickford Aerospace amp Defense MaineHealth AdvancePierre Foods Ortho Clinical Diagnostics New Balance LL Bean etc

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 15: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

What is the Cost of Poor Quality

bull Prevention (0 ndash 5)ndash Capability studies training pilot

projects design reviews

bull Appraisal (10 ndash 50)ndash Audits inspecting incoming raw

materials inspecting final products

bull Failure (40 ndash 80)ndash Internal Repairs sorting failure

reviewsndash External Recalls warranty expenses

litigation Levels of Product Costs

Prevention

Appraisal

Failure(Internal amp External)

Quality Council of Indiana (2001) CSSBB Primer p III-62

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 16: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Why Does Variability Matterbull Money

-4 -3 -2 -1 0 1 2 3 4

xA_

LSL

egndash Minimum thickness of a steel beamndash Amount of cheese on a pizza

-4 -3 -2 -1 0 1 2 3 4

xB_

Prob

abili

ty

Normalized Critical to Quality (CTQ) parameter

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 17: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

SAMPLE PROJECTS

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 18: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Project Filling Bottlesbull Background Sole proprietorship manufactures markets amp sells ~$70kyear of

niche hair care productsbull Problem statement Reduce the current ~19 secbottle filling time by 30 or ~57

secbottlebull Process improvements

ndash Reduced movement of operator (~69 secbottle)ndash Eliminated funnel by adding filling valve (~37 secbottle)

bull Resultsndash Reduced filling time by 56 or ~106 secbottle ndash Payback period of ~4 days on $120 capital investment

Originalprocess

1 Queue empty bottles

2 Move pot

3 Place funnels and fill

4 Replace pot

5 Return to counter

6 Queue filled bottlesImprovedprocess

1 Place 1 bottle in sink

2 Fill bottle via valve

3 Return filled bottle

6

45

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 19: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Project Reduce Mold Change Timesbull Background Manufacturer performed ~12 mold changes

week each requiring ~233 mins

bull Problem statement Reduce the mold change time by 25 (or 58 mins) to 175 mins

bull Process improvements ndash Improved flow of information ndash Reduced searching (processing) by creating cart

parking lotndash Reduced movement by transporting all components

in single trip

bull Resultsndash Mold changes reduced by ~27 to 168 minsndash Annual labor savings of ~350 hours

Thermoforming mold change

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 20: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Project Chemical Processingbull Background Research into biomedical applications of seaweed-

extracted polysaccharides is limited by the rate and efficiency of current extraction methods

bull Problem statement Reduce the 10-50 mass loss of ethanol within the polysaccharide water bath and centrifuge extraction process

bull Process improvements ndash Identified how mass loss occurredndash Introduced re-usable centrifugal tubes and water bath mounting

systembull Results

ndash Net savings of $4300 year primary in laborndash Water bath setup time reduced from ~65 mins to ~03 mins (95

reduction)ndash Successful processes increased from ~40 to 100

Re-usable centrifugal tube

Original centrifugal tube

Water bath mounting system

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary
Page 21: Lean Six Sigma - IEEE · 2018. 11. 15. · Lean Six Sigma • Lean Manufacturing (LM) – a continuous improvement methodology that seeks to understand value (i.e., what customers

Summarybull Lean Manufacturing seeks to decrease wastes amp add value

bull Six Sigma seeks to reduce variation and defects to near zero levels

bull Lean Six Sigma initiatives can improve profitability viandash Waste reductionsndash Faster deliveryndash Improved qualityndash Reduced variation in productsndash Reduced overhead costs associated with product development

ldquoI know of no more encouraging fact than the unquestionable ability of man to elevate his life by a conscious endeavorrdquo- Henry David Thoreau

Ref Thoreau (1910) Walden p 117

Brett Ellis brettellismaineedu

  • Lean Six Sigma
  • Brett D Ellis PhD PE CSSBB
  • Lean Six Sigma
  • Lean manufacturing
  • ValueNon-Value Added (VNVA)
  • 7 Types of Muda (ie Wastes)
  • 5S
  • Continuous Flow Efficient amp Faster
  • Poke-Yoke Mistake Proofing
  • Lean Manufacturing Example
  • Six Sigma
  • Six Sigma 6σ
  • Why is Six Sigma Important
  • Why is Six Sigma Important
  • What is the Cost of Poor Quality
  • Why Does Variability Matter
  • Sample projects
  • Project Filling Bottles
  • Project Reduce Mold Change Times
  • Project Chemical Processing
  • Summary