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Lean Six Sigma

Why Lean Six Sigma?

Six Sigma is a disciplined approach to problem solving, but not necessarily focused on the improvement of process cycle time.

Lean is focused on the improvement of process throughput and the reduction of process/product costs, but not necessarily the improvement of a process by the reduction of variation.

Lean Six Sigma brings both disciplines together in a complementary fashion, to improve product and process efficiency along with reducing variation and waste.

 

Lean Six Sigma tools:

Explanation:

DMAIC Process

The process means just what the terms imply.  A disciplined means for comprehensive problem solving.

Note: The DMAIC process is a problem-solving tool, not a quality system.

Define the Improvement Opportunity
Measure performance of the process (current)
Analyze the data quantified in the measure phase
Improve the process
Control the process

Five Why’s

A method to get to the root cause of a problem. Participants don’t stop asking the question “Why” until further questioning produces no answers.

Five “S” (or 5 “C”)

A process to improve the working environment (in part, or as a whole)

Sort (Clear out)
Straighten (Configure)
Shine (Clean and Check)
Standardize (Conformity)
Sustain (Custom and Practice)

SIPOC

A tool to ensure all pertinent components of a Critical to Quality, CTQ, process are considered during process definition or analysis.

Supplier—Who supplies the input to the process?
Input—Is input required to perform process?
Process
Output
Customer

Statistical Process Control, SPC

A tool utilized to determine process capability, potential areas for improvement, and the measurement of success in the implementation of improvement methods. Useful for determining the capability of a process.

Control Charts

  • X-Bar and R charts
  • C Charts
  • P Charts
  • nP Charts
  • U Charts

Value Stream Process Mapping

Used to show the “value added” portions of a process as well as the “non-value added” portions of a process.

Note: “Non-value added” portions of a process may be essential, i.e. regulatory components.

Process Mapping
Value Stream Analysis

DFSS, Design for Six Sigma

One tool used in the DFSS methodology is DMADV. This provides the discipline of the DMAIC process with a focus on a new product or process, as opposed to improving an existing product or process.

Define the Project
Measure customer requirements
Analyze concepts for the design
Design the product
Verify design performance

FMEA, FMECA

Based upon Mil. Std 1629 A, in use since the 1940’s.

A valuable tool when used in the design phase of a product.  A risk and criticality based approach to improve product and mitigate potential failures with appropriate safeguards prior to release.

Failure. What is the failure?
Mode.  What is the way in which the failure may happen?
Effect.  What is the effect of the failure?
Criticality.  How critical is the failure?
Analysis.  What has our analysis shown as means to prevent the failure, and resultant effects of failure?