ELECTIVES
Lean is a way of thinking. It is all about continuous
improvement eliminating all forms of waste in a
process.
Started out with Henry Ford assembly line in the
early 1900's
Then shortly after WWII Taichi Ohno and Kiichiro
Toyoda took aspects of Ford's work with new ideas
for continuous improvement and created the
Toyota Production System.
Lean Manufacturing is all about making a product
in the most efficient and effective manner,
while looking for ways to continuously improve.
Lean Manufacturing is a significant aspect of being an
Industrial Engineer
Walter Shewhart introduce control chart
W. Edward Deming introduced the concept of
continual improvement
CF Gauss introduced normal curve
1950 continual improvement was introduced
Bill Smith father of Six Sigma
Frederick Winslow Taylor
- Father of scientific management
Lean Manufacturing
- applied in the manufacturing of a product
or delivery of a service
Define
- Identify the project goals and all customer
deliverables
Analyze
- Determine root causes of any defects.
Measure
- Understand current performance.
Improve
- Establish ways to eliminate defects and
correct the process
Control
- Manage future DMA process performance.
linearity.
DMADV
- is employed when existing processes do
not meet customer conditions, even after
optimization, or when it is required to
develop new methods.
Verify
- Ensure process designed meets customer
needs and performs adequately.
Design
- Create a process that meets customer
needs and expectations.
Analyze
- Determine root causes of any defects.
Measure
- Understand current performance.
Define
- Identify the project scope and all customer
deliverables.
Bias
- is the difference between the observed
average measurement to the true or
reference value.
Linearity
- is the difference in Bias value in contrast to
the normal operating range of the
measuring instrument.
Stability
- refers to the capacity of the measurement
system to produce the same values over
time when measuring the same sample
Repeatability
- is the variation between successive
measurements of the same part or
characteristic by the same person using the
same gauge.
Reproducibility
- is the difference in the average of the
measurements by different people using
the same instrument when measuring the
identical characteristic on the same part.
Histogram
- Which is a type of bar chart that visualizes
both attribute and variable data of a
product or process and helps users show
different distribution of data and amount of
variation within a process.
Pareto Chart
- Is a combination of a bar and line table that
visually summarizes a set of data.
Fishbone Diagram 3. Resource allocation
- Collects all items and thoughts then uses 4. Organizational Relationships
brainstorming techniques to analyze and 5. Outcomes Maintenance
identify the most powerful underlying cause 12 Critical Success Factors for Six Sigma
for that problem. Effectiveness
5 Whys Analysis 1. Management involvement and
- To find the main cause of an issue, they commitment
should constantly ask the question "Why" 2. Cultural change
3.4 Million 3. Communication
This statistics-based approach aims to 4. Organization infrastructure
reduce the number of defects to less than 5. Training
2.4 per million, controlling quality and 6. Linking Six Sigma to business strategy
achieving near perfection. 7. Linking Six Sigma to customer
Toyota 8. Linking Six Sigma to human resources
- refers to the capacity of the measurement 9. Linking Six Sigma to suppliers
system to produce the same values over 10. Understanding tools and techniques within
time when measuring the same sample Six Sigma
Stability American telecommunications 11. Project management skills
company founded by by brothers Paul 12. Project prioritization and selection
Galvin and Joseph Galvin in 1928. Four Importance of top level commitment
TQM/IS09000 1. Setting the Tone
(Total Quality Management/International 2. Ensures resource allocation
Organization for Standardization). 3. Overcoming Resistance
Stafistical process evaluation 4. Encourages employee participation
- they measure defect rates in all processes Six Demonstrating commitment
and uses quality level in measuring process 1. Leading by Example
capability. 2. Allocating budget and resources
Business strategy 3. Participating in improvement projects
- they gain a competitive edge in quality, cost 4. Adaptability
and customer satisfaction 5. Long-term
Management philosophy 6. Be visible
- they work smarter based on data analysis 6 Benefits of strong commitment
and teamwork. 1. Increase efficiency
Leadership Traits in Six Sigma (Good Leader) 2. Higher customer satisfaction - Improve
VISION employee morale
LEADERSHIP & DEDICATION 3. Bottom-line impact
COMMUNICATION 4. Team cohesion
INDEPENDENCE 5. Long term sustainability
ADMINISTRATION OF TRANSFORMATION 6 Stakeholder Involvement ( these stakeholders
Leadership Traits in Six Sigma (Bad Leader) can include:)
1. LACK OF EMPATHY 1. Employee
2. INFLEXIBILITY 2. Customer
3. BAD LISTENING SKILLS 3. Supplier
4. INCONSISTENCY 4. Inventors
5. SELF-CENTERED PEOPLE 5. Communities
5 CHALLENGES IN LEADERSHIP FOR SIX SIGMA IN 6. Regulatory bodies
BRIEF
1. Resistance to change
2. Organizational culture
8 Give at least 5 out of 10 secrets of success stand
out and can be share
Endurance
Early cost reduction
Top level management
Voluntary basis
Full time BBS
Demanding BB course
Design of experiments
One metric and one number