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Introduction to Lean Six Sigma
Terms in this set [27]
Six Sigma
Refers to a product or process that produces only three defects [or errors] out of every million opportunities.
Sigma Level
Sigma level is a quality metric that measures the level of performance of a process based on the number of defects per million opportunities [DPMO] in that process, compared to the near-perfection level of Six Sigma, which equates to 3.4 defects per million opportunities.
Benefits of Six Sigma
Customers get more quality, reliability and value.
Associates get more job security, teamwork, and
participation.
Shareholders get more profitability, market share, and return on investment.
Defect
Any failure of a product or service to meet customer requirements. The "customer" may be the external consumer, or may be the next step of an internal process.
Philosophy Lean Six Sigma
Removing variability from upstream operations that are inputs to a process will yield defect-free outputs
Goal Lean Six Sigma
Identify the significant inputs, then tackle the root causes of their adverse variability through improved process controls, error-proofing, redesign for manufacturability, and other methods.
Y=f[X]
Means output [Y] is a transfer function [f] of inputs [X], variability in the inputs causes defects, or errors, in the output. Transformation of inputs by the process into an output is represented by f.
Central Activities of a Lean Six Sigma Project
Identifying and resolving upstream root causes of variation [defects]
Defects Per Million Opportunities [DPMO]
When a process is improved to the point to 3 or less defects in each million opportunities, process reaches Six Sigma performance level.
Purpose of Lean Six Sigma
Business Success defined by:
1] Reduced cost
2] Increased market share
3] Improved customer satisfaction
4] Faster time to market
5] Increased revenue and profits
Lean Six Sigma
A comprehensive and flexible system for achieving, sustaining and maximizing business success [objective, tangible, bottom-line results]. Six Sigma is uniquely driven by close understanding of customer needs, disciplined use of facts, data, and statistical analysis, and diligent attention to managing, improving, and reinventing business processes."
Lean Methods
Developed to attack the waste associated with the flow of material and information - the velocity, or speed, of a process from beginning to end.
Value Stream Map - Purpose
Define Current and Desired Future State
Visual map of the value stream created to show the flow of materials and information. Value stream maps have been widely used as a central component of the Toyota Production System. They include information on takt time
[demand rate], inventory levels, changeover times, and manpower. The goal of Value Stream Mapping is to identify the primary process steps and activities that require process improvement.
Value Stream Map - Definition
Visual map of the value stream created to show the flow of materials and information. Value stream maps have been widely used as a central component of the Toyota Production System. They include information on takt time [demand rate], inventory levels, changeover times, and manpower. The goal of Value Stream Mapping is to identify the primary process steps and activities that require process improvement.
Value Stream Map - DMAIC Alignment
Define
Takt Time - Definition
The time it should take to produce one unit if production is matched to demand. Takt time = net available production time [after breaks] per period divided by average customer demand during that same period.
Takt Time - Purpose
Line Balancing
Takt Time - DMAIC Alignment
Define / Measure
Little's Law / Theory of Constraints - Definition
Little's Law is an equation that expresses the relationship between processing speed, the level of work-in-process inventory, and process cycle time. The equation states: Cycle Time = Items-In-Process / Throughput Volume Per Unit of Time
Little's Law / Theory of Constraints - Purpose
Reduced Work-In-Process, Reduced Cycle Time
Little's Law / Theory of Constraints - DMAIC Alignment
Improve
Quick Changeover - Definition
Methodology used to reduce the time to execute process set-ups required when changing between different products or services. Lean systems achieve lower inventory levels through small lot sizes, which in turn require Quick Changeovers. See also SMED.
Quick Changeover - Purpose
One Piece Continuous Flow
Quick Changeover - DMAIC Alignment
Improve
Kanban / Pull Scheduling - Definition
System where inventories of downstream operations are replenished by pulling work-in-process inventory on demand from upstream operations as the downstream operations exhaust their inventories. See also Just-In-Time.
Kanban / Pull Scheduling - Purpose
One Piece Continuous Flow
Kanban / Pull Scheduling - DMAIC Alignment
Improve
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