Combining LeanSix Sigma

1
Combining Lean/Six Sigma Ideation in New
Product/Service Development

• Rob Bryant, CSC Lean/Six Sigma Program Leader
  Corporate Vice President of Quality
• January 15, 2009

2
Lessons Learned (right up front)

• The company has to have the desire to change
  (baseball story)
• Align the change with a strategic initiative
• Collect subjects for Strategic Initiatives from
  Management but also Employees through an Ideation
  Event.
• Passionate Executive sponsorship
• An endorsed Project charter
• Knowledgeable and excited team
• Provide an amnesty program
• Provide an effective award program
• Set realistic goals
• Apply Lean first
• Belts must have time to work projects

3
Lessons Learned (right up front)

• Only apply the tools that fix the problem-not the
  entire arsenal.
• Deliver low-quick wins, then continue the longer
  projects
• Assemble a passionate team willing to visualize
  the steps, count the cost, pay the price, and
  never give up!
• Flattering introduction of team members
• Develop a phased approach for large improvements
• Conduct follow-up meetings
• Share the results of projects and the entire
  program
• Train all Sr. Management at the Awareness or
  Champion level
• Ensure finance measures the results, not L6S
  practitioners
• Put a strong board in place and control the
  program (especially for Global companies)
• Eliminate the defect or very strong C in DMAIC
  (Hawthorne Effect)

4
Three Components to a Successful Six
Sigma/Ideation Program

• Support system
• Infrastructure for the project/belt selection and
  training
• Finance engagement
• Management support at all levels
• Put Ideation in place (contact information on
  later slide)
• Belts
• Crisp process for identifying the right belts
  (Green Belt,Black Belt, Master Black Belt)
• Conducting training
• Projects
• Crisp process for project selection
• Pick projects aligned with Strategic Initiatives
• Choose Projects from Ideation Events
• Matching the belts with the projects
• Improve processes by increasing customer/employee
  satisfaction, revenue, and performance while
  reducing costs, waste, and defects

5
My Own Walk Through Change

• The fall that took it all
• My three thoughts on the way down
• This is really going to hurt
• Did I kiss my family goodbye?
• I will survive
• Paralysis
• Surgeries

Hard times do not dictate the outcome you do.
6
How They All Fit TogetherMethodology Analogy
Solving Problems with Lean/Six Sigma Ideation
Lean/ Six Sigma
Six Sigma
Ideation
Lean
Design for Six Sigma
Kaizen
7
Which projects do you choose? Gain momentum by
aligning business problems and strategic
initiatives.
Strategic Initiatives 1. Reduce time to receive
parts from vendors. 2. Reduce the cost of bidding.
Rejects
Rework
Inspection Costs
Testing
Scrap
Warranty
Pricing andBilling Errors
Morale, Productivity,Turnover
Long CycleTimes
CustomerAllowances
Lost Sales
ExcessiveOvertime
Lost CustomerLoyalty
Time withDissatisfiedCustomers
ExcessInventory
Expediting Parts
Late Delivery
Late Product Introduction
RevenueLeakage
OverdueReceivables
Eng. Change Orders
Lean/Six Sigma attacks the entire iceberg
systmatically resulting in higher quality, lower
cost, timeliness, and improved customer
satisfaction.
8
LEAN your processes to measure productivity and
sustain your deployments. This will reduce

• Loops
• Non-value added approvals
• Bottlenecks
• Series steps
• Unnecessary complexity
• Non-value added steps
• Process time/cycle time
• Problem steps
• Set-up time
• Manual effort
• Rework
• Pushes (insert pulls)

9
The Power of Lean!
Apply Lean first, then Six Sigma.
10
The Resistance to Change

• Change is uncomfortable
• We seem to have all the time in the world to
  rework it, but no time to eliminate the defect
  (do it right the first time
• If a manager will not get onboard, improve
  everything around them so their poor performance
  is obvious and the boss makes them comply.
• The best and worst day of my life (Dr. and Jon)
• The Daddy Book
• The risk of not having a plan Pop

The first step toward change is the hardest.
11
About Ideation

• Idea Central is a web-based application
  designed to help organizations maximize the
  benefits from the creativity, expertise and
  knowledge of employees, customers, suppliers and
  other trusted third parties. The software
  contains specialized features to help focus idea
  generation towards strategic business objectives,
  and to capture, develop and share those ideas
  across an organization, in a secure manner. Idea
  Central also provides a state-of-the-art review
  process designed to elicit high quality insight
  and evaluations from decision makers, with
  minimum administrative overhead.
• Contact Information
• 332 Newbury Street2nd FloorBostonMA
  02115sales_at_imaginatik.com
• Tel [phone]Fax [phone]

12
Getting Started

• Executive Sponsor Develops the Idea
• Capture Idea with Ideation Questionaire (helps to
  hone in or critical issues)
• Executive Challenge to employees involved through
  E-Mail containing
• The problem to be solved
• The link to the Ideation Portal
• Brief description of what an Ideation Event is (I
  will draft for your approval)
• The deadline of the Ideation Event (normally two
  weeks).
• Contain a High-Level Flow Chart (this depicts
  current process and scope and will reduce
  unrelated comments, suggestions and questions)

13
Getting Maximum Benefit from the event

• Employees suggest root causes and solutions
• Ideation sends e-mails to all parties involved
  throughout process and Theres a strong report
  mechanism.
• Other employees comment and rate the ideas
• Peer Reviews of root causes and associated
  solutions
• Affinity Diagramming to assist reviewers see
  similar ideas
• Formal Reviews of root causes and solutions
• Reaching Conclusions with SMEs and Reviewers
• Choose the best ideas
• Complexity/Criticality Analysis

14
Conduct a Criticality/Complexity Analysis on the
Ideas
15
Conducting Lean Events on high CC Ideas

• In order to ensure a successful Lean Event, we
  need to perform the following Pre-event Steps
• Fill-out a Project Charter
• Identify an executive sponsor and champion.
• Ensure SMEs and necessary management are
  available for the 3 day event (can make the
  decisions).
• Ensure a room w/adequate support is available
  (internet computer overhead capable).
• Ensure a report-out to Sr. management is
  pre-scheduled at the end of the event.
• Gather as much data (or have access to a
  database) relative to the Xs (most significant
  failures). Conduct Gage RR on the data if
  necessary to ensure data integrity.
• Collect benchmark data if possible.
• Gather (or have access to) the Voice of the
  Customer (interview internal external
  customers).

16
Lean Event Steps

• Review all information together to gain
  understanding.
• Use Lean methods to get on the same page.
• Use QFD (House of Quality) to gather the
  requirements of the process and ascertain the
  steps causing the greatest pain.
• Review the current model - Walk the current
  process identifying rework, loops, bottlenecks,
  parallel steps, defects, excessive time and
  costs, manual effort, pushes, non-value-added
  forms, approvals, steps.
• Discuss the relationship between Sigma Level, the
  number of steps and yield.
• Lean views steps from 3 perspectives 1) Steps
  creating value as perceived by the customer 2)
  Non-value added steps but necessary (regulatory,
  customer req, etc) 3) Non-Value added steps that
  should be eliminated, combined, reduced or
  converted to a 1 or 2.
• Do Pareto Chart on most costly steps, longest
  times, etc. and be prepared to spend your time on
  those parts of the New Model.
• Produce a Fishbone of largest issue to record
  causes.

17
Lean Event Steps (Contd)

• Produce Value Stream Map depicting solutions and
  new times, costs, defects, etc.
• Automate steps as possible (Forced Control,
  Shutdown, Warning or Sensory Alert)
• Build in process check points and measures (who
  does it-what should be measured)
• Produce Cost Benefit Analysis of New Process
• Reductions in measurement units w/new process
• What are barriers to new model and how to address
  them
• Assign tasks with names and dates
• Report Out on New Model to Sr. Management. Get
  their input, make assignments to close gaps, get
  approval.
• Execute the plan, follow-up, report on status,
  close project and ensure controls stay in place
  on the new process, improve process as necessary.
• Review of Conclusions with Exec Management and
  Process Owners
• Put Fixes in Place
• Track Performance
• Improve areas needing improvement using Lean
  and/or Six Sigma tools

18
Taking the First Step Toward Change

• Who moved that leg?
• The first step is the hardest the 30 hall
• The miracle walk
• The row across America
• Jon at USNA
• Challenge yourself and others to deploy improved
  processes using L6S tools.
• Dont give up until the change is in place
• You have to crawl beforeyou can walk, run, or fly

19
Backup SlidesAbout the Speaker
20
Walking Through Adversity, Author Rob Bryant,
Published by HCI
21
A Few Endorsements

• Former First Lady Barbara Bush I am so glad to
  have this opportunity to send my warmest
  greetings and congratulations to Rob and Wanice
  Bryant. Rob's determination certainly is an
  enormous inspiration. George joins me in sending
  our very best wishes.
• Governor Arnold Schwarzenegger, California
  Congratulations on your accomplishment of a
  cross country trip on a row-cycle. That was a
  monumental achievement, and I wish to
  congratulate you on both your mental and physical
  endurance. I deeply admire what you have done!
• Tom Landry, Former Dallas Cowboys Head Coach
  Rob is a coachs kind of guy, he never quits.
  Rob set two world records even though he is
  paralyzed from the waist down. He is a man of
  faith, and I am looking forward to walking with
  him in heaven some day. (Quote from a network
  program which Tom Landry hosted.)
• Author and Speaker Zig Ziglar Rob Bryant is an
  effective speaker! He had our staff laughing one
  minute and crying the next. He is an
  inspirational man who, by example as well as a
  very effective presentation, is able to give
  encouragement and hope to those who have the
  privilege of listening to him. He will be a hit
  with your group. Robs message is timely and
  challenging one that you will long remember.
  Rob has a champions heart and is an
  encouragement and inspiration to us all.
• Author and Aerobics Authority Kenneth H. Cooper,
  M.D. "Rob, I am overwhelmed by your
  accomplishment in the face of unbelievable
  obstacles! You are worthy of the highest praise
  for motivating millions of people to improve
  their health and fitness.

22
A Few Endorsements (Contd)

• Minister Joni Erickson Tada Rob believes that
  we should never give up! God has given us the
  ability to either accept our situation, or change
  it. (Quote from a broadcast)
• USA Todays Ben Brown The next time you moan
  about 20 minutes on an exercise bike, think about
  Rob Bryant, a 35-year old aerospace engineer, who
  has just finished a four-month, 3,280 mile
  workout on an oar-equipped tricycle ... Though
  paralyzed from the waist down, he also pushed and
  pulled himself with crutches over 24 miles from
  Fort Worth to Dallas!
• Former Senator Chuck Robb, Virginia Rob, it is
  with great pleasure that I congratulate you for
  holding two world records and am honored that I
  could greet you at the finish line at the
  Capitol. Congratulations to you and your family.
• Former Governor William Donald Schaefer,
  Maryland It is with great pleasure that I
  congratulate you. This grueling journey, which
  more than tripled the previous world record, is
  an outstanding and inspirational achievement. I
  hope you are as proud of your Maryland roots as
  we are of you.
• State Senator Roy Dyson, Maryland Mr. Speaker,
  I rise today to pay tribute to Rob Bryant's
  employer and to Rob Bryant. Rob Bryant has been
  a paraplegic since 1982 when he fell 55 feet from
  an oil rig. Despite his handicap, he has just
  completed a courageous 3,280 mile Row Across
  America. Mr. Speaker, it is both an honor and a
  pleasure to salute Rob Bryant today.
• Former Congressman Pete Geren, Texas Mr.
  Speaker, strength and perseverance rolled into
  town this week in the heart of Rob Bryant. He has
  just completed a 3,280 mile journey from Los
  Angeles to Washington, DC on a hand propelled row
  cycle. Rob Bryant is an author and stands tall in
  our eyes. He is truly an inspiration to all of
  us.
• Senator Kay Granger, Texas I commend you for
  your past and future accomplishments, your
  generosity, and for being the special person for
  whom we all have the greatest respect and
  admiration.

23
Business Accomplishments

• CSC Corporate Vice President for Quality
• Assisted DynCorp in increasing revenue from 900M
  to 2.1B in just four years as a direct report to
  the President
• Certified Six Sigma Master Black Belt Trainer
  led over 100 teams and studies resulting in over
  100M in savings/revenue/improvements for all
  divisions of CSC
• Malcolm Baldridge Sr., Examiner for the National
  MB Award for the Dept. of Commerce assessing
  quality for the President of the United States
• Served on the President Bush Business Advisory
  Council for two years
• Served as an editor for a book called Quality for
  Dummies and has written several published
  articles/papers for journals such as Quality
  Digest, Six Sigma Magazine, and others
• Quality Certifications include ISO-90012000,
  TQM, Process Management, ITIL, CMMI, Six Sigma
  Master Black Belt, Business Excellence, and
  Malcolm Baldridge

24
Personal Accomplishments

• Published author of three non-fiction books and
  negotiating with literary agent on two more (a
  fiction thriller and fictional love stories)
• HCI (known for the Chicken Soup for the Soul
  series) has now released Bryants latest book,
  Walking Through Adversity
• Motivational speaker with lnternational Speakers
  Bureau (RobBryant.com) has spoken to over 500
  business and civic organizations, churches,
  hospitals, universities, high schools, and many
  other groups
• Two world records longest walk by paraplegic
  (24 miles) and rowing 3,280 miles on a row
  machine (Guinness Book of World Records,
  1992-2000)
• Nominated for Texas Businessman of the Year by
  the Texas Republican Committee
• Nominated as a National Republican Committee
  Honorary Chairman and attended a dinner with
  President G.H. Bush in that capacity
• Past President of LeTourneau Alumni Association
• LeTourneau University Instructor Principles of
  Self Management Administration Theory and
  Practice Strategic Management Ethics and
  Entrepreneurship

25
Experience. Results.