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An introduction to lean six sigma
The document provides an overview of Lean Six Sigma as a process improvement methodology. It discusses key Lean concepts like eliminating waste, standardizing processes, and continuous improvement. It also explains Six Sigma's statistical focus on reducing defects and variation. The DMAIC process of Define, Measure, Analyze, Improve, Control is introduced as the framework for process optimization projects using Lean Six Sigma.
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An introduction to lean six sigma
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- 2. An Introduction toLean Six Sigma “We don’t know what we don’t know. We can’t act on what we don’t know. We won’t know until we search. We won’t search for what we don’t question. We don’t question what we don’t measure. Hence, we just don’t know.” Dr. Mikel Harry
- 3. Process Improvement 1. InitialPerception of problem 2. Clarify Problem 3. Locate Point of Cause 4. Root Cause Analysis 5. Design Solutions 6. Measure Effectiveness 7. Standardize
- 4. Lean Six SigmaProcess Improvement • Lean Six Sigma Seeks to improve the quality of manufacturing and business process by: – identifying and removing the causes of defects (errors) and variation. – Identifying and removing sources of waste within the process – Focusing on outputs that are critical to customers Define Measure AnalyzeImprove Control
- 5. Lean Six SigmaProcess Improvement • LSS is a management philosophy that seeks to drive a quality culture change through a multi-level based program Level Training Green Belt LSS Methodology and basic tool set Black Belt Green Belt content plus advanced data analysis Master Black Belt Black belt content plus program management, leadership skills, some advanced tools
- 6. 1930 19501900 Ford Assembly Line Guinness Brewery Shewhart IntroducesSPC Gilbreth, Inc. •Management Theory •Industrial Engineering Deming •14 Points •7 Deadly Diseases Toyota Production System Lean Six Sigma Timeline
- 7. 1990 20001980 Motorola Introduces Six Sigma Just– in–Time SPC Lean Mfg. TQM AlliedSIgnal GE Adapt LSS to Business Processes Lean Six Sigma Timeline
- 8. Background on Lean •Lean comes out of the industrial engineering world • Taiichi Ohno – Toyota Production System. – 1940s-1950s company was on verge of bankruptcy – Dynamics of industry were changing – moving from mass production to more flexible, shorter, varied batch runs (people wanted more colors, different features, more models, etc). • Ohno was inspired by 3 observations on a trip to America – Henry Ford’s assembly line inspired the principle of flow (keep products moving because no value is added while it is sitting still) – The Indy 500 – Rapid Changeover – The American Grocery Store – led to the Pull system – material use signals when and how stock needs to be replenished
- 9. Path To Lean TheoryWaste is Deadly Application 1. Define Value – act on what is important to the customer 2. Identify Value Stream – understand what steps in the process add value and which don’t 3. Make it flow – keep the work moving at all times and eliminate waste that creates delay 4. Let customer pull -- Avoid making more or ordering more inputs for customer demand you don’t have 5. Pursue perfection -- there is no optimum level of performance Focus Flow Focused Assumptions Non-Value added steps exit Results Reduced cycle time
- 10. Waste Defined Wastes HealthcareExamples Transport 1. Moving patients from room to room 2. Poor workplace layouts, for patient services 3. Moving equipment in and out of procedure room or operating room Inventory 1. Overstocked medications on units/floors or in pharmacy 2. Physician orders building up to be entered 3. Unnecessary instruments contained in operating kits Motion 1. Leaving patient rooms to: • Get supplies or record • Documents care provided 2. Large reach/walk distance to complete a process step Waiting 1. Idle equipment/people 2. Early admissions for procedures later in the day 3. Waiting for internal transport between departments Over-Production 1. Multiple signature requirements 2. Extra copies of forms 3. Multiple information systems entries 4. Printing hard copy of report when digital is sufficient Over-Processing 1. Asking the patient the same questions multiple times 2. Unnecessary carbon copying 3. Batch printing patient labels Defects 1. Hospital-acquired illness 2. Wrong-site surgeries 3. Medication errors 4. Dealing with service complaints 5. Illegible, handwritten information 6. Collection of incorrect patient information Skills 1. Not using people’s mental, creative, and physical abilities 2. Staff not involved in redesigning processes in their workplace 3. Nurses and Doctors spending time locating equipment and supplies 4. Staff rework due to system failures
- 11. Lean Foundations • StandardizedWork – people should analyze their work and define the way that best meets the needs of all stakeholders. – “The current one best way to safely complete an activity with the proper outcome and the highest quality, using the fewest possible resources” – Standardized not Identical – mindless conformity and the thoughtful setting of standards should not be confused – Written by those who do the work. • Level loading – smoothing the workflow and patient flow throughout the hospital. • Kaizen – continuous improvement
- 12. Lean Methods • KaizenEvents (or SCORE events) – Planned and structured process that enables a small group of people to improve some aspect of their business in a quick, focused manner. • Select • Clarify • Organize • Run • Evaluate • 5S – this methodology reduces waste through improved workplace organization and visual management – Sort, Store, Shine, Standardize and Sustain • Kanban – a Japanese term that can be translated as “signal,” “card,” or “sign.” – Most often a physical signal (paper card of plastic bin), that indicates when it is time to order more, from whom, and in what quantity.
- 13. Lean vs. SixSigma • Lean tends to be used for shorter, less complex problems. Often time driven. Focus is on eliminating wasteful steps and practices. • Six Sigma is a bigger more analytical approach – often quality driven – it tends to have a statistical approach. Focus on optimizing the important steps – reducing defects. • Some argue Lean moves the mean, SixSigma moves the variance. But they are often used together and should not be viewed as having different objectives. – Waste elimination eliminates an opportunity to make a defect – Less rework means faster cycle times • Six Sigma training might be specialized to the “quality” department, but everyone in the organization should be trained in Lean
- 14. VOC vs. VOP Voiceof Customer Voice of Process The Voice of the Process is independent of the Voice of the Customer Sigma Capability Defects per Million Opportunities % Yield 2 308,537 69.15% 3 66,807 93.32% 4 6,210 99.38% 5 233 99.98% 6 3.4 99.99966%
- 15. What’s good enough? 99%Good (3.8 Sigma) 99.99966% Good (6 Sigma) 20,000 lost articles of mail per hour (based on 2,000,000/hr) 7 articles lost per hour Unsafe drinking water for almost 15 minutes each day 1 unsafe minute every 7 months 5,000 incorrect surgical operations per week 1.7 incorrect operations per week 2 short or long landings daily at an airport with 200 flights/day 1 short or long landing every 5 years 2,000,000 wrong drug prescriptions each year 680 wrong prescriptions per year No electricity for almost 7 hours each month 1 hour without electricity every 34 years
- 16. Goals of LeanSix Sigma LSL USL Customer Target DefectsDefects Prevent Defects by Reducing Variation LSL USL Customer Target Defects Prevent Defects by Centering ProcessLSL USL Customer Target Meet Customer Requirements
- 17. What Makes aGood Lean Six Sigma Project? • There is no known solution • The root cause is not known • The problem is complex and needs statistical analysis • The problem is part of a process • The process is repeatable • A defect can be defined • Project will take 3-6 months • There are data available
- 18. The DMAIC Methodology •Define – describe the problem quantifiably and the underlying process to determine how performance will be measured. • Measure – use measures or metrics to understand performance and the improvement opportunity. • Analyze – identify the true root cause(s) of the underlying problem. • Improve – identify and test the best improvements that address the root causes. • Control – identify sustainment strategies that ensure process performance maintains the improved state.
- 19. Define • Define Scopeof the Problem – Document the Process – Collect and Translate the Voice of the Customer • Determine Project Objective and Benefits – Define Metrics and Defects – Establish Preliminary Baseline – Develop Problem & Objective Statements – Estimate Financial Benefit
- 20. Define (continued) • CreateProject Charter – Confirm Improvement Methodology – Define Project Roles and Responsibilities – Identify Risks – Establish Timeline – Managerial Buy-in • Focus here is on the problem
- 21. Measure Measure what ismeasurable, and make measurable what is not so” – Galileo • Define “As Is” process – Value stream map/process flow diagram • Validate Measurement System for Outputs – Don’t assume your measurements are accurate – measuring system must accurately tell what is happening • Quantify Process Performance – Collect data (Y’s) – Examine process stability/capability analysis
- 22. Analyze • Identify PotentialCauses (X’s) • Investigate Significance of X’s – Collect data on x’s – Graphical/Quantitative analysis • Pareto Chart • Fishbone Diagram (cause and effect) • Chi Square Test • Regression Analysis • Failure Mode Effects Analysis • Identify Significant Causes to focus on (y=f(X)) – Evaluate the impact of x’s on y • Here you identify the critical factors of a “good” output and the root causes of defects or “bad” output.
- 23. Improve • Generate PotentialSolutions • Select & Test Solution • Develop Implementation Plan
- 24. Control • Create Control& Monitoring Plan – Mistake proof the process – Determine the x’s to control and methods – Determine Y’s to monitor • Implement Full Scale Solution – Revise/develop process – Implement and evaluate solution • Finalize Transition – Develop transition plan – Handoff process to owner
Editor's Notes
- #7 Transition effect for timeline, slide 1 (Basic) Tip: This transition works well for graphics that horizontally span more than one slide. To reproduce the shape effects on this slide, do the following: On the Home tab, in the Slides group, click Layout, and then click Blank. On the Home tab, in the Drawing group, click Shapes, and then under Block Arrows click Chevron (second row, eighth option from the left). On the slide, drag to draw a long, horizontal chevron shape. Select the chevron. Under Drawing Tools, on the Format tab, in the Size group, do the following: In the Shape Height box, enter 0.7”. In the Shape Width box, enter 9.48”. Drag the chevron until the right end is beyond the right edge of the slide, and the left end of the chevron is approximately one inch to the right of the left edge of the slide. Select the chevron. Under Drawing Tools, on the Format tab, in the Shape Styles group, click the arrow next to Shape Fill, point to Gradient, and then click More Gradients. In the Format Shape dialog box, click Fill in the left pane, select Gradient fill in the Fill pane, and then do the following: In the Type list, select Linear. Click the button next to Direction, and then click Linear Up (second row, second option from the left). Under Gradient stops, click Add or Remove until a total of four gradient stops appear in the drop-down list. Also under Gradient stops, customize the gradient stops as follows: Select Stop 1 from the list, and then do the following: In the Stop position box, enter 0%. Click the button next to Color, and then under Theme Colors click White, Background 1 (first row, first option from the left) Select Stop 2 from the list, and then do the following: In the Stop position box, enter 36%. Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 213, Green: 219, Blue: 221. Select Stop 3 from the list, and then do the following: In the Stop position box, enter 73%. Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 178, Green: 190, Blue: 194. Select Stop 4 from the list, and then do the following: In the Stop position box, enter 100%. Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 213, Green: 219, Blue: 221. Also in the Format Shape dialog box, click Line Color in the left pane, and then select No line in the Line Color pane. Also in the Format Shape dialog box, click Shadow in the left pane, and then do the following in the Shadow pane: Click the button next to Presets, and then under Outer click Offset Bottom (first row, second option from the left). In the Transparency box, enter 60%. In the Size box, enter 100%. In the Blur box, enter 4 pt. In the Angle box, enter 90°. In the Distance box, enter 3 pt. Also in the Format Shape dialog box, click 3-D Format in the left pane. In the 3-D Format pane, under Bevel, click the button next to Top, and then under Bevel click Circle (first row, first option from the left). Next to Top, in the Width box, enter 4 pt, and in the Height box, enter 4 pt. On the Insert tab, in the Text group, click Text Box, and then on the slide, drag to draw the text box. Enter text in the text box, select the text, and then on the Home tab, in the Font group, select Gill Sans MT Condensed from the Font list, enter 26 in the Font Size box, click Bold, click the arrow next to Font Color, and then under Theme Colors click White, Background 1, Darker 50% (sixth row, first option from the left). On the Home tab, in the Paragraph group, click Center to center the text in the text box. Select the text box. On the Home tab, in the Clipboard group, click the arrow under Paste, and then click Duplicate. Repeat this process to create a total of three text boxes. Click in each of the two duplicate text boxes, and then edit the text. Drag the text boxes onto the chevron shape to form a row. Press CTRL+A to select all the objects on the slide. On the Home tab, in the Drawing group, click Arrange, point to Align, and then do the following: Click Align to Slide. Click Align Middle. Press and hold SHIFT, and then select all three text boxes. On the Home tab, in the Drawing group, click Arrange, point to Align, and then do the following: Click Align to Slide. Click Distribute Horizontally. To reproduce the animation effects on this slide, do the following: On the Animations tab, in the Transition to This Slide group, click More, and then under Push and Cover click Push Left. On the Animations tab, in the Transitions to This Slide group, in the Transition Speed list, select Slow.
- #8 Transition effect for timeline, slide 3 (Basic) Tip: This transition works well for graphics that horizontally span more than one slide. To reproduce the shape effects on this slide, do the following: On the Home tab, in the Slides group, click Layout, and then click Blank. On the Home tab, in the Drawing group, click Shapes, and then under Block Arrows, click Chevron (second row, eighth option from the left). On the slide, drag to draw a long, horizontal chevron shape. Select the chevron. Under Drawing Tools, on the Format tab, in the Size group, do the following: In the Shape Height box, enter 0.7”. In the Shape Width box, enter 9.48”. Drag the chevron so that the left end is beyond the left edge of the slide, and the right end is approximately one inch left of the right edge of the slide. Select the chevron. Under Drawing Tools, on the Format tab, in the Shape Styles group, click the arrow next to Shape Fill, click Gradient, and then click More Gradients. In the Format Shape dialog box, click Fill in the left pane, select Gradient fill in the Fill pane, and then do the following: In the Type list, select Linear. Click the button next to Direction, and then click Linear Up (second row, second option from the left). Under Gradient stops, click Add or Remove until a total of four gradient stops appear in the drop-down list. Also under Gradient stops, customize the gradient stops as follows: Select Stop 1 from the list, and then do the following: In the Stop position box, enter 0%. Click the button next to Color, and then under Theme Colors click White, Background 1 (first row, first option from the left). Select Stop 2 from the list, and then do the following: In the Stop position box, enter 36%. Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 213, Green: 219, Blue: 221. Select Stop 3 from the list, and then do the following: In the Stop position box, enter 73%. Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 178, Green: 190, Blue: 194. Select Stop 4 from the list, and then do the following: In the Stop position box, enter 100%. Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 213, Green: 219, Blue: 221. Also in the Format Shape dialog box, click Line Color in the left pane, and then select No line in the Line Color pane. Also in the Format Shape dialog box, click Shadow in the left pane. In the Shadow pane, click the button next to Presets, under Outer click Offset Bottom (first row, second option from the left), and then do the following: In the Transparency box, enter 60%. In the Size box, enter 100%. In the Blur box, enter 4 pt. In the Angle box, enter 90°. In the Distance box, enter 3 pt. Also in the Format Shape dialog box, click 3-D Format in the left pane. In the 3-D Format pane, under Bevel, click the button next to Top, and then under Bevel click Circle (first row, first option from the left). Next to Top, in the Width box, enter 4 pt, and in the Height box, enter 4 pt. On the Insert tab, in the Text group, click Text Box, and then on the slide, drag to draw the text box. Enter text in the text box, select the text, and then on the Home tab, in the Font group, select Gill Sans MT Cond from the Font list, enter 26 in the Font Size box, click Bold, click the arrow next to Font Color, and then under Theme Colors click White, Background 1, Darker 50% (sixth row, first option from the left). On the Home tab, in the Paragraph group, click Center to center the text in the text box. Select the text box. On the Home tab, in the Clipboard group, click the arrow under Paste, and then click Duplicate. Repeat this process to create a total of three text boxes. Click in each of the two duplicate text boxes, and then edit the text. Drag the text boxes onto the chevron shape to form a row. Press CTRL+A to select all the objects on the slide. On the Home tab, in the Drawing group, click Arrange, point to Align, and then do the following: Click Align to Slide. Click Align Middle. Press and hold SHIFT, and then select all three text boxes. On the Home tab, in the Drawing group, click Arrange, point to Align, and then do the following: Click Align to Slide. Click Distribute Horizontally. To reproduce the animation effects on this slide, do the following: On the Animations tab, in the Transition to This Slide group, click More, and then under Push and Cover click Push Left. On the Animations tab, in the Transitions to This Slide group, in the Transition Speed list, select Slow.