Lean Six Sigma production occurs when each operation in the value stream produces exactly what the next operation needs, exactly when they need it, with near perfect quality and minimal waste!
Lean Six Sigma Value
Proposition
• What competitive advantages would you have if you could:
> Reducing manufacturing and overhead costs by 20%?
> Deliver products in 50 to 80% less time?
> Free up capital through a 75 to 90% reduction in inventories?
> Improve labor productivity by 40 to 50%?
> Improve quality by a factor of 10x or 100x?
> Reduce the cost of poor quality by 50%?
> Reduce time-to-market by 50%?
The Lean Enterprise
• Lean companies use less of everything than do more traditionally
managed companies:
- Half the human effort in the factory,
- Half the manufacturing space
- Half the investment in tools
- Half the engineering hours to develop a new product in half the time,
- Less than half the inventory
Lean Six Sigma Strategies
•
Implement Continuous Flow Processing
•
Use Pull not Push Scheduling
b.) Supermarket Pull With Kanban
C.) Heijunka
•
Control Quality at the Source
d.) Source Inspection & Error proofing
•
Develop Flexible Production Equipment
e.)Quick changeovers - SMED
•
Manage Overall Equipment Effectiveness
f.)Total Productive Maintenance
Lean Six Sigma
Organization
Lean Six Sigma Project Plans
• For each project identify:
a a.) What
type of improvement is needed
b.) The
reason why the improvement is needed
c.) How much improvement is needed (the gap)
d d.) The
expected benefits – just categories at this time
1.)
We will add financial estimates later
e.) The
value stream champion
f.) The
project team leader
1.) The
Lean / Six Sigma black belt
g.) The
key personnel to include on the project team
h.) The Project start date
i.) The project review schedule
j.) The expected completion date