Applying LeanSix Sigma

1
Applying Lean/Six Sigma to Life Cycle
Management Effective Efficient Products and
Services
VSE Corporation Wednesday March 15, 2006
2
Discussion

• LSS Focus within TACOM and the Army
• Overview of Enterprise Excellence
• Elements of LSS Success
• LSS Deployment
• Does it Work

3
AMC Lean Six Sigma Policy

• The focus of Lean Six Sigma are the
• Inefficiencies
• Waste
• Excess Bureaucracy
• Delay
• Prevent the Warfighter from receiving the support
  required to accomplish the mission.

It is our duty to improve quality, speed, and
agility and eliminate waste in both our
industrial and our administrative
processes General Benjamin S. Griffin U.S. AMC
Policy Letter
The focus is on the Warfighter
4
Enterprise Excellence Model
Effectiveness
Quality Management System
Voice of the Customer
Six Sigma Project Selection
Six Sigma Process Control
Six Sigma Process Improvement
S

• Focused QS-R
• Payback
• Infrastructure support
• Enterprise map
• DMAIC methodology

• Infrastructure
• Process documentation
• Management responsibilities
• Implementation
• ISO-9000

• IPPD
• Product-to- Process link
• Performance/process requirements
• CDOV methodology

• Process mapping
• Process FMEA
• Statistical process control
• Measurement systems evaluation
• Process capability

• Descriptive statistics
• Inferential statistics
• Analysis of variance
• Linear contrasts
• Design of experiments

Efficiency
Enterprise Excellence
Lean Assessments
Leaning the Enterprise
Lean Project Selection
CMI

• Value stream analysis
• Takt Times
• Seven forms of waste
• 5S
• Routing Analysis
• Process Availability
• Work content analysis

• Yield
• Scrap
• Rework
• RTR
• Cycle time
• HPU
• CPU
• Product family
• DMALC methodology

• Planning and control
• ABC matl handling
• Service work centers
• JIT/Kanban
• Work center plan
• Level loading
• Mixed model
• Workable work

• Enterprise metrics
• Balanced scorecard
• Project selection
• Six Sigma initiatives
• Kaizen events

5
Structured Disciplined - Accountable

• Structured Lean Six Sigma Tools
• Disciplined Lean Six Sigma Methodologies
• Accountable Lean Six Sigma Infrastructure

Elements of Lean Six Sigma Success
6
LSS Tools
Project Selection Matrix
Interrelationship Diagram
Q F D
Kanban
SPC
FMEA
Inferential Statistics
Design of Experiemnts
Requirements Generation
RSM
MSE
Kano Analysis
Brainstorming
Relationship Digraph
PDPC
Value Stream Map
ANOVA
Voice of the Customer
Work Content Analysis
Process Map
Process Optimizer
Structured Tool Set for Design Management
Administrative Industrial Processes
7
LSS Methodologies
DMAIC
DMALC
DFLSS
Disciplined Improvement Process
8
Establish the E2 Infrastructure
ESC/Review Panel
Champions
Master Black Belts
Black Belts
Green Belts
Team Members
Accountability
9
Deployment
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Does It Work?

• A Few Examples

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Does it Work?

• L/6s achievements at one Army activity over the
  last three years
• 3.0B estimated life cycle savings
• 70M 201 VE validated returns
• Improvement in all aspects of QSR
• P Performance, Reliability, Customer
  Satisfaction (96 of projects)
• Cost (72 of projects)
• S Schedule (68 of projects)
• R Risk (87 of projects)
• Improvement projects in
• Engineering (41)
• Production (31)
• Management/Administration (28)

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Where is it happening in the Army and Army
Suppliers

• American Ordnance
• Picatinny Arsenal
• Joint Munitions Command
• Alliant Techsystems
• General Dynamics OTS
• Radford AAP
• Milan AAP
• Army Rock Island Arsenal
• Pine Bluff Arsenal
• PEO-CS-CSS

• RDECOM-ARDEC
• TACOM Tank-Automotive and Armaments Command
• Army CECOM R2 Office
• Army Research and Development
• PEO Ammunition
• Army Benet Laboratory
• PEO-GCS
• Anniston Army Depot
• 21st TSC USAREUR

13
If a soldier pulls the trigger and hears a click,
he does not care if the round or the weapon was
inexpensive!
Effective and Efficient Products and Processes