Industry Standard Approach

1
What is Lean Six Sigma?
Industry Standard Approach
Credibility and Communication with Customers
Robust problem solving
DMAIC
Links problems and opportunities from viewpoint
of customer to the processes that deliver, then
starts improvement process
VOC CTQ Process
Eliminates waste and cost in process and
significantly reduces customer defects
Lean Six Sigma
2
Benefits of Lean Six Sigma
Results
Level of Service
Speed of Prod. Dev.
Customer Satisfaction
Profitability
Cost
Leadership Development
Black Belts 1 each year in full time
Culture

• Bias for Action
• Factual
• Customer Focused

3
Why do Teams and Efforts Fail?
and 6 Tools to Drive Success
Organizational Change
6 LSS Tools
Succeed
Stake Holder Analysis
15
Action Events
Tollgate
Dashboard
Process Map
FMEA
Why?

1 Sense of Urgency
85
Fail
2 Not enough Communication
3 Declaring Victory too early
Personal Change
4 Personal resistance
Succeed
10
90
Fail
4
Dashboards
R/Y/G
J
F
M
A
M
J
J
A
S
O
N
D
PRINCIPLES
BENEFITS

• Pareto (80/20) 80 focus on process 20 focus
  on results
• Yf (x)
• Process Ownership
• Benchmarks
• Visual
• Long term sustained gains through series of short
  term wins

• Communicates objectives and results
• Benchmarks are challenges

5
Process Maps or Road Map
PRINCIPLES
BENEFITS

• Map Actuals usually different than you think
• Create future state a) vision b) gaps
  identified and assigned
• Get your hands dirty
• Ask why 5 times

• Allows targeted improvement at bottlenecks
• Many Just do its
• Communicates actions

6
Stakeholder Analysis
People
Level of Commitment
Customer
Key Person 1
Key Person 2
o
Enthusiastic
o
o
Help
Compliant
x
Hesitant
x
Indifferent
Uncooperative
x
Opposed
Hostile
PRINCIPLES
BENEFITS

• Identify key people and gaps to long term support
• Develop individual action plan and communications
  plan
• WI / FM
• Enlist other leadership to help move this

• Upfront addressing of biggest failure mode

7
Strategic FMEA (Simplified)
Predicted
R P N
R P N
Failure Mode
Who/ When

Cause
S
O
D
Action
S
O
D
Effect
PRINCIPLES
BENEFITS

• Anticipate major risks
• Fix big ones before they are problems
• Have response plan for others
• Work only the top 10-20

• Ready for most problems
• Rapid response

8
Tollgates
D
M
A
I
C
(Realization)
PRINCIPLES
BENEFITS

• Aim small, miss small
• Small wins along the way keep up motivation
• Stakeholders should have deliverable at each
  tollgate
• Dont declare victory too soon (realize)

• Force discussion of success, progress, failure

9
Action Events (Kaizen)
Typical Mtg.
How long for teams to complete
close
actions
50-60 value
review
intro
Never
Action Event
Action Event
close
actions
90 value
review
intro
Never
PRINCIPLES
BENEFITS

• Intense, highly planned event
• Learn by doing
• Get everyone involved

• Fast results
• Buy-in
• NIH in reverse

10
Summary

• Get Started
• Even poor usage of these tools will get results
• Learn more about Lean Six Sigma

References for Learning

• What is Lean Six Sigma? by George, Rowlands,
  and Kastle
• Leading Change by John Katter
• The Lean Six Sigma Pocket Toolbook by George,
  Rowlands, Price, Maxey
• iSix Sigma.com