Lean Six Sigma Comprehensive Implementation Model

1
Lean Six SigmaComprehensive Implementation Model
TOOLS
PROCESS
ANALYTICS
TECHNOLOGY
Charter, VOC,VSM, SIPOC, CTQ, Scorecards
Define
Brainstorming, MSA, Walkthrough,
CE, 5S, KPOV and KPIVs, RTY,
Benchmarking
Measure
Fishbone Diagrams, Pareto Charts, Control
Charts, Process Capability, FMEA,
Statistical Analyses, Layout and Process
Flow Analyses
Analyze
Kaizen Event, Contingency Planning, Pilot, DOE,
Optimization
Improve
Business Intelligence Decision Support
Systems Dashboards Performance Management Systems
Standardize Process, Training,
Visual Aids, Mistake Proofing, Document
Benefits
Control
2
Roadmap for Lean Six Sigma
Deployment
3
Define Phase

• Project Charter
• Create problem statement and estimate project
  benefits
• Gain consensus on project scope and stakeholders
• Identify needed resources
• Voice of the Customer (VOC)
• Identify Critical to Quality (CTQ) Issues
  (customer and process)
• Process Maps
• Use Value Stream Mapping to outline broad process
• Use SIPOC to establish context
• Use detailed flowcharts to map process
• Scorecards
• Identify Fundamental (overall) objective and
  possible metric (Big Y)
• Identify specific means objectives and metrics
  (small ys)
• Describe multidimensional performance
  assessment of process

4
Measure Phase

• Brain Storming / Interviewing for Operational
  Definitions
• Measurement Systems Analysis
• Process Walkthrough for Line Balancing
• Identify each KPOV and corresponding KPIV
• Tabulate Causes (KPIV) and Effects (KPOV) in a
  Cause and Effect Matrix
• Identify and evaluate metrics for each output and
  input variables
• Outline Data Collection Strategies
• Implement the 5S Methodology to address above
  issues
• Benchmark processes in other organizations

5
Analyze Phase

• Process Analysis
• Calculate Process Capability (Cpk)) and Rolled
  Throughput Yield (RTY)
• Analyze Layout and Process Flow
• Graphical Modeling
• Use Fishbone diagram to map causes and effects
• Root Cause/Statistical Analysis
• Brainstorm to prioritize inputs
• Use Charts and Descriptive Statistics to evaluate
  each output and inputs
• Use Pareto Charts
• Use Correlation Analysis
• Cause and Effect Modeling
• Use Influence Diagrams to map relationships
  between inputs, process outcomes, and overall
  performance metrics
• Use time-series and regression modeling to
  estimate relationships
• Simulate Models and Identify Process Improvement
  Strategies

6
Improve Phase

• Conduct a Kaizen event to develop an
  implementation plan
• Empower stakeholders to create future state and
  outline benefits
• Identify potential obstacles and resolve them
• Implement feasible changes immediately
• Pilot test improved process
• Simulate potential strategies
• Test various assumptions
• Design experiments and gather data
• Implement Improved process and technology
• Implement Decision Support Systems for continuous
  improvement
• Provide analytical support for continuous
  evaluation of process
• Utilize new technology
• Create contingency plans

7
Control Phase

• Standardize
• Document the new process
• Create Standard Operating Procedures (SOPs)
• Create and deliver training
• Orientation to all employees
• Just-in-time to new teams
• Post visual aids to reinforce new process
• Obtain final approval of documented project
  benefits
• Identify process owner
• Utilize control charts to continue to monitor
  process
• Implement a Process Management Control System
  (PMCS)