services portfolio - nebula.wsimg.com
TRANSCRIPT
Achieving Operational Excellence
Services Portfolio
www.abacusteam.ca
Abacus Team Inc.
Siemens
Copyright Abacus Team Inc. 2015
Who is Alex Boussetta
• Extensive experience and education in continuous improvement: Lean and Six Sigma; Certified Master Black Belt (MBB)
• Extensive experience and education in project management, including projects over 30 Millions $, related to industrial engineering, product introduction, information systems
• Specialties: Lean thinking, Six Sigma with operational and business processes, DFSS, Project Management, Quality Management
Diplomas and Certifications: P. Eng., M. Eng, Six Sigma Master Black Belt (MBB), PMP, SCRUM Master Certified (SMC)
Copyright Abacus Team Inc. 2015
Who is Alex Boussetta
• Alex Boussetta has over 21 years of operational experience. He participated in many company transformations, turn around initiatives, and led continuous improvement and operational excellence deployments.
• Prior to consulting, Alex Boussetta was Corporate Director of Lean at MAAX, Director of Operations at Triton Electronik, and most recently Director, Global Supply Chain and Devices Quality at Blackberry.
• He holds a VIP award for his project management work at General Electric, as well as a five star award from BlackBerry for product reliability breakthroughs.
Copyright Abacus Team Inc. 2015
Roadmap to Process Excellence
Process Excellence
Advanced Lean and Black Belt
tools
Lean Daily Management
System
Waste and Variation Reduction
Lean Six Sigma Kaizen, Green
Belt tools
Problem solving
Copyright Abacus Team Inc. 2015
Roadmap to process excellence
Process Excellence
Advanced Lean and Black Belt
tools
Lean Daily Management
System
Waste and Variation Reduction
Lean Six Sigma Green Belt tools
Problem solving
Copyright Abacus Team Inc. 2015
Root Cause Analysis - 8D
1. Problem description
2. Establish containment
3. Root cause identification
4. Corrective action
5. Validation of corrective action
6. Prevention of recurrence
7. Plan recognition
8. Close out problem resolution
Copyright Abacus Team Inc. 2015
Change Management and Leadership
Resistance
phase
Anger, fear
Listen
Denial phase
This can’t be
happening
Provide
information
Questioning
phase
What is it really ?
What will be my
involvement ?
Coach and
encourage
Exploration
phase
We should be OK
with this
Train and
encourage
Commitment
phase
It’s not that bad,
and actually is
better in some
ways
Recognize the
effort
Copyright Abacus Team Inc. 2015
Roadmap to process excellence
Process Excellence
Advanced Lean and Black Belt
tools
Lean Daily Management
System
Waste and Variation Reduction
Lean Six Sigma Green Belt tools
Problem solving
Copyright Abacus Team Inc. 2015
Lean Daily Management System Elements
Leader Standard Work
Visual Controls
Daily Accountability
Process
Ensure that leaders that own the process focus on the critical elements within the material and information flow of their value streams. The critical elements are identified through Control and Assurance.
provide an immediate understanding of a situation or condition
Ensure that leaders that own the process communicate and share issues and drive problem solving within their value streams
Discipline&
Teaching
Copyright Abacus Team Inc. 2015
ESV OTD
Working
Capital
OTBooked hoursTRT
Defects
Quality
Tier I meeting –
CellsWhen: Shift start
5 minutes
Tier II meeting –
Engine Line / CR areaWhen: 7:30 AM
15 minutes
...
...
Wip Snags
Shortages
TRT
...
Tier III meeting –
SiteWhen: 8:30 AM every day or
week
60 minutes
Business Governance,
Information System and
Visual Management in
line with the company
scorecard
Hours Absence
CONQ
Absence
WIP LAR
OT
TRT
Absence
WIP
LAR
IN/OUT
HS&E
HS&E
Action plan: daily and
systemic issues
Action plan: daily and
systemic issues
Action plan: daily and
systemic issues
Copyright Abacus Team Inc. 2015
Roadmap to process excellence
Process Excellence
Advanced Lean and Black Belt
tools
Lean Daily Management
System
Waste and Variation Reduction
Lean Six Sigma Green
Belt tools
Problem solving
Copyright Abacus Team Inc. 2015
DOCUMENTREALITY
REALITYCHECK
REFRESHERTRAINING
FIRST DAY DAYS 2, 3 &/or 4 LAST DAY
KICK-OFF:GOALS etc
We get these
We do these
We measure progress
with these
Goals
Driver Measures
/Event Ojectives
Countermeasures
(LM Tools)
ID THE WASTE
PLANCOUNTERMEASURES
MAKE CHANGE
REVIEW PROGRESSTO-DO LIST
MAKE CHANGE
MAKE CHANGE
TO-DO LISTREVIEW PROGRESS
VERIFY CHANGE
QUANTIFYRESULTS
MAKE THIS THE NEWSTANDARD
SUMMARIZE ANDCELEBRATE
EVENT SUMMARYGOALS AND RESULTS
PLAN NEXT EVENT &
DO IT
AGAIN!
N
S
EW LEAN?
TOOLS
DRI
VE
RS
DRIVER MEASURE /
COUNTERMEASURE
MATRIX
TO-DO LIST
TEAM
LEADER
MEETING WITH
CONSULTANT
TO-DO LIST
TEAM
LEADER
MEETING WITH
CONSULTANT
TO-DO LIST
TEAM
LEADER
MEETING WITH
CONSULTANT
Kaizen Event
Copyright Abacus Team Inc. 2015
Waste (muda)
Copyright Abacus Team Inc. 2015
Summary Sheet and Target SheetScope and team:SIPOC
Capital investment
Force field analysis
ObservationData collection plan
Brainstorm on scenarios
Plan countermeasures
Improvement idea form
Newspaper
Flow techniques, SMED
Root cause analysis
5S, TPM
Pull: Kanban
Poka Yoke, Jidoka, Autonomation
Selection grids
LEAN
Roadmap
Prepare the
Kaizen
Make and verify
Changes
Value
Value Stream
Flow
Pull
Perfection
Copyright Abacus Team Inc. 2015
Mission statement
Scope and team:SIPOC
Project Management Plan (10 dimensions)
Force field Stakeholder analysis
Scenarios
Functional analysisValue Engineering
Flow techniques
5S, TPM, SMED
Pull: Kanban, Heijunka
Poka Yoke
Selection gridsPugh principle and creativity
DOE, Performance prediction
Pilot and Implementation plan
Lean 6
Define
Improve
Green Belt&
Black BeltTools
Copyright Abacus Team Inc. 2015
Roadmap to process excellence
Process Excellence
Advanced Lean and Black Belt
tools
Lean Daily Management
System
Waste and Variation Reduction
Lean Six Sigma Green Belt tools
Problem solving
Copyright Abacus Team Inc. 2015
Black Belt Roadmap
Recognize
•Strategic plan
•SWOT analysis
•Hoshin Kanri
•Value Stream Improvement Plan
•Customer complaints and surveys
•Kano model
•Scorecards, Dashboards, bowling charts
•COPQ
•Benchmarking
•Tree technique
•Selection grids
•Multi GenerationalProject Plan
Define
•Mission statement
•Scope and team:SIPOC
•5W2H
•Project Management Plan (10 dimensions)
•Force field analysis
•Stakeholder analysis
Measure
•Voice of the customer, Needs, Y, X, Takt time
•Survey design
•Kano Model
•QFD, Benchmarking
•Brainstorming, Ishikawa, 5W, 5W2H, ICUKU
•Process mapping,
•Value Stream Mapping
•VA/NVA and otheranalysis types
•Risks: FMEA
•Observation
•Data collection plan, sampling
•Measurement system analysis
•Process capability:
•Cpk, Ppk, Z, DPMO, yields – Normal and non normal
Analyze
•Critical X
•Graphical analysis
•Chronological analysis
•Statistical analysis
•Sample size calculation
•Hypothesis testing, ANOVA
•Correlation and regression
•Multivari charts
•Selection of the factors to improve
•Change management
•Communication, presentations
•Functional analysis, Value Engineering
Improve
•Scenarios
•Functional analysis
•Value Engineering
•Flow techniques
•5S, TPM, SMED
•Pull: Kanban, Heijunka
•Poka Yoke
•Selection grids
•Pugh principle and creativity
•Workshops guidelines and facilitation
•Overview of Design for Six Sigma for products
•Process design methodology including simulation
•Design of experiment
•Loss function
•Pilot and Implementationplan
Control
•Visual management
•Control plan
•Control charts
•Standard work
•Standard workcombination sheets
•Transfer of power
•Lessons learned
•Update of MGPP
•Celebrate
•Post mortem and audits
•Quality system and standardized work
•Evaluation of the gains
Copyright Abacus Team Inc. 2015
Project Management
• Scope: Orientation, definition, limits
• Quality: Tests, validation
• Time: Milestones, deadlines, duration, critical path
• Cost: Budget, cost of product / process
• Human resources: Planning, quantity and profiles
• Procurement: Suppliers, work
• Communication: Planning, meetings, reviews
• Stakeholders: Engagement, Decision Makers
• Risks: Unknowns, delays, expenses, resistance to change
• Integration: These 10 dimensions with the environment and events
According to the Project Management Institute
Copyright Abacus Team Inc. 2015
GOAL
OBJECTIVES
MANAGEMENT CREATES STRATEGIES
SUPERVISORS CREATE ACTION PLANS
ASSOCIATES CREATE RESULTS
ANA
Safety
EmployeeInvolvement
Delivery
Quality
Cost
Early LaunchInvolvement
orm Team
Heijunka
orm Team
Prevent ProblemRecurrence
rmT
Engage Mgmt.At Worksite
QualitySafety Delivery EmployeeInvolvement Cost
Hoshin Kanri – Strategy Deployment
Copyright Abacus Team Inc. 2015
Hoshin Kanri – Strategy Deployment
Level 1: Linking Corporate objectives to Function / BU
Level 2: Linking Function / BU Objectives to its Leadership Team
Level 3: Linking the Leadership Team to their Directors, Managers
Copyright Abacus Team Inc. 2015
Design for Six Sigma and Reliability
Cost of changes
At different
Stages of
the product
development
Market Top level Detailed
Research Design Design Production
(VOC) (concept)
1
X 10
X 100
X 1000
DMAIC
projects
Copyright Abacus Team Inc. 2015
Define the mandate
Strategic plan and objectives
Business case
Project mandate
Define and prioritize the target markets
Market study
Market segmentation
Choice of differentiation
Identify the customer needs (Voice of the
customer)
Interviews
Surveys
Focus groups
Ethnography technics (observation)
Kano analysis
Identify the requirements, and the key
requirements, in order of importance to the
customer
QFD, FMEA
Functional analysis
Affinity diagrams
Set the measurable performance objectives , in
accordance with the customer and the
competition
Value engineering
Multi generation product plan (platform definition)
Benchmarking, competitive comparison
Generate Concepts
Brainstorming
Creativity tools (ex: TRIZ, creativity templates)
Identify Project and product risks
Feasibility studies
Risk management
FMEA
Value stream mapping
Select the best concept Pugh emergence principle (matrix)
Apply DFX principles
Functional analysis
DFX: Design for manufacturing, assembly,
testing, maintenance, obsolescence checklists
Define
Identify
Characterize
Design for Six Sigma and Reliability
Copyright Abacus Team Inc. 2015
Identify and prioritize the design parameters
according to the key requirements QFD
Build the transfer functions
Theory, software models
Sigma based tolerance design and gap analysis
Transfer functions
Prediction scorecards
Identify the lower level parameters (detailed
design parameters) and transfer functions
QFD
Theory, software models
Sigma based tolerance design and gap analysis
Transfer functions
Prediction scorecards
Reduce sensitivity of key parameters to
variations and noise , including risks
simulation
Design of experiment
Prediction scorecards
Return to the DFX principles
Functional analysis
Value engineering
DFX: Design for manufacturing, assembly,
testing, maintenance, obsolescence checklists
Set tolerances Prediction scorecards
Plan the pilot, validation and the tests (design
tests)
Validation planning matrix
prototype definition
Validate and test actual performance Pilot or prototype assessment
Prediction scorecards
Complete the product development process
steps
Capability verification
EVOP
Validate
Optimize
Design for Six Sigma and Reliability
Copyright Abacus Team Inc. 2015