SIX SIGMA

ORIGIN
Introduced by Motorola, USA in 1981
A registered service mark and trademark of Motorola Inc.
Combined with lean manufacturing to form lean six sigma
Early adopters included Honeywell and GE(Jack Welch)
Originated as a set of practices designed to
Improve manufacturing processes
Eiminate defects

MEANING
Based on the notion that a spread of 6 sigmas on either side of the
process mean leads to virtually no defects
DEFECT Anything leading to customer dissatisfaction or nonconformance

Shift in process mean?

Increase in process standard deviation?

MEAN & VARIATION

Center
Performance

Reduce
Variation

Target
Long term 1.5 sigma shift to account for long term normal
process mean shift and standard deviation change

DPMO
OPPORTUNITY : Any area within a product, process, service, etc.
where a defect can be produced
Short term conformance to 6 sigma transforms to long term
conformance to 4.5 sigma
Hence
A six sigma process as one that produces 3.4 defective parts per
million opportunities (DPMO).
-3.4 parts per million beyond a point that is 4.5 standard
deviations above or below the mean
-3.4 DPMO of a "Six Sigma" process in fact corresponds to 4.5
sigmas, namely 6 sigmas minus the 1.5 sigma shift
-This takes account of special causes that may cause a
deterioration in process performance over time

DMAIC PROBLEM SOLVING METHOD

Define

Sets the context and objectives for project improvement

(goals and customer (internal/external) deliverables).

Measure Determines the baseline performance and capability of

the process youre improving.
Analyze Uses data and tools to understand the cause-and-effect
(root causes) of your performance problems.
Improve Develops the modifications that lead to a validated
improvement (creating performance breakthroughs).
Control

Establishes plans and procedures to ensure that the

improvements are sustained in the future.

IMPLEMENTATION
Executive leadership

Set up vision; empower members

Champions
Responsible for overall six sigma implementation

Master Black Belts

In-house coaches for six sigma
Black Belts
Apply six sigma methodology to specific projects

Green Belts & Yellow Belts

Work on Six Sigma application along with other job
responsibilities

A six sigma black belt takes his son to work

http://www.youtube.com/watch?v=3PeesW-UoqY&feature=related

5S

The 5Ss

BENEFITS
Higher Safety Levels
Defects Easier to Detect
Improved productivity (ownership)
Less Searching (Misplaced Items Evident Earlier)
Less Motion
Less Frustration
Successful 5S program is an excellent predictor of the greater
Lean Initiative success.

Seiri(Sort): Clearout and Classify

Seiton(Set In order): Configure

Seison(Shine): Clean and Check

Seiketsu(Standardize): Conformity
Shitsuke(Sustain): Custom and
Practice

5S: The Foundation for Everything

Seiri: Sort
Involves:
Organizing Work Area
Keeping Only Necessary items to Perform Daily Work
Everything Else is Recycled, Discarded or Stored.
Improves Communication Between People
Quality and Productivity are increased

Seiton: Simplify
Items arranged in best location to promote work flow.
In line with physical Work Flow
Use visual controls (signs, color-coding, labels)

A place for
everything and
everything in
its place

Seiso: Shine
Continuous upkeep, control and maintenance of the work area
Clean as you Go
Shine means Clean to inspection
Think from the view of a visitor

Seiketsu: Standardize
Consolidate the Previous 3 Ss and Create Visual Management.
Provide Consistent Approach to How Tasks Should be Done
Maintained by Visual Controls
Document Shine Process (consistent between shifts)
Standardize Across Organization Create and Share Best Practices

Shitsuke: Sustain
Last StageEveryone follows the Rules (Discipline and
Commitment)!
Teams are empowered to improve and maintain workplace
Create an Environment to Sustain
Set up an audit schedule for the previous 4 Ss
Incorporate 5S into you daily management

Benefit of 5S: Example

Seiri (Sort):
My workstation Uses Numbers from 1 to 30
Circle the numbers from 1 to 30 in numerical order in 15 seconds

Benefit of 5S: Example

Seiton (Simplify):
Workstation is now SORTED (removed unnecessary)
Circle the numbers from 1 to 30 in numerical order

Benefit of 5S: Example

1

14

12

26

30

23

16

19

15

22

18

11

28

20

10

17

24

21

29

25

13

27

Workstation is now SIMPLIFIED (straightened and right side up)

Circle the numbers from 1 to 30 in numerical order

Benefit of 5S: Example

1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Workstation is STANDARDIZED (sequence and size)

Easier method for circling numbers from 1 to 30

Benefit of 5S: Example

1

10

11

12

15

16

23

24

18

25

26

19

14

20

21

22

28

29

30

Workstation has 5S. What numbers are missing?

With Sustain, easier to recognize abnormalities

5S at Toyota
http://www.youtube.com/watch?v=nHutkkfUpDs&feature=related

REVIEW
5S is the Foundation for Lean and Consists of:
Sort
Simplify
Shine
Standardize
Sustain: Custom and Practice
Must be a Reason for Doing (Safety, Quality, etc.)
5S Evaluation Provides Level of Understanding for Building Lean
Foundation

QUERIES??

What do you see?

Commitment to 5S
Product layout?? Really?

JUST IN TIME
(JIT)
Also known as Toyota Production System

A management philosophy that strives to eliminate

sources of manufacturing waste by producing the right
part in the right place at the right time
Improve processes to reduce cushions(inventory, capacity,
etc.)

JIT VISA Ad
http://www.youtube.com/watch?v=U86bTrsdShg

JIT PHILOSOPHY
Inventory is waste - Adds cost without adding much value
Reducing inventory exposes existing manufacturing weaknesses
Reduce inventory which does not compensate with mfg. process
issues
Work on existing process to improve reliability and require less
inventory
In short
the right material, at the right time, at the right place, and in
the exact amount

A PULL SYSTEM!

INVENTORY - MUDA
Management may be tempted to keep stock to hide production
problems Inventory in any form serves as a buffer and hides
problems and weaknesses in the mfg. system

SOME TERMINOLOGY
Muda Japanese term for non value added activity (waste)
Kaizen Continuous improvement through identification and
elimination of Muda
"Kai" means "change"
"zen" means "good (for the better)"
Ongoing improvement involving everyone
Highly focused, action oriented
Never ending improvement efforts

IMPLEMENTING JIT
Reduce setup/changeover time Reduce inventory required during
the setup time
Flexible and multi-skilled workforce Move employees wherever
required as per the demand
Reduce lot sizes Reduce average inventory levels
Reduce lead times Reduce safety stock
Preventive maintenance Spot and tackle problems before
occurrence and prevent disruption; reduce variability and thus
reduce safety stock

IMPLEMENTING JIT
Build supplier relationships
Ensure quality of supplies
Reduce variability of supplies
Synchronize supply with production Frequent supplies
spread throughout the production time instead of one time supply