Lean Six Sigma
Lean Six Sigma is a methodology applied within the projects in the companies aiming at solving the problems using DMAIC cycle: Define – Measure – Analyze – Improve -Control. The methodology combines the principles of Lean (reducing waste, continuous improvement, value stream optimization) with specific Six Sigma statistical tools to determine root causes and making the best decisions.
– COUNSELLING for practical application of this methodology in solving specific problems.
– Training for acquiring Lean / Six Sigma and combining them in problem-solving projects using DMAIC cycle.
Training comprises the following :
Module 1 – Six Sigma – Yellow Belt (click here!)
Module 2 – Detailed phases of DMAIC cycle:
Definition: The project objectives, project requirements.
• Project requirements, CTQ forms – Voice of the Customer ( VOC ); Project Charter draft;
• Problem and objective definition
• Establish the team
• Identify resources
• SIPOC diagram (Supply- Input – Process -Output – Customer); House of quality
• Mapping the chart of the processes involved in the project (High Level Process Map)
• Tree structure of what to do: WBS (Work Breakdown Structure)
• Project stages, activity plan and reporting times (milestones)
• Analysis of those involved directly or indirectly by the project (Stakeholder Analysis)
Measurement: Measurement of the actual parameters of the process (what is process performance?), Which are the proper targets we are planning to achieve through the project ?
• Making detailed chart of the processes
• Writing requirements – VOC – Voice of the Customer
• Establish measurement parameters, of how to collect data on faults (Data collection Plan), measurement units; benchmarking
• Analysis of current measurement system – Gauge Repeatability and Reproducibility (Gauge R & R); validation of the system to be used in the project
• Measurement of the process for identifying the relationships between inputs and outputs: y = f(x)
• Calculation of current Six Sigma level.
Analysis: determining the causes of faults in the processes involved in the project
• Identify and eliminate wastage in the processes and among the processes by applying Lean tools: 7Wastes and Values Stream Analysis.
• Measurement of the parameters of products (services) and processes to find out the source of variations in the process. Use of appropriate tools to highlight: histograms, Pareto chart, Run Chart coins, Scatter Plot, etc.
• Finding the causes using Mind Mapping, Ishikawa diagram, five whys , Ishikawa diagram, etc. in correlation with statistical analysis, hypothese testing (Continuous & discrete ), etc.
• Establishing determinant factors x (Vital Few) of process relationship Y=f(x)
• Define performance goals that we set in the project
Improvement: generation and testing of new solutions, establishing the solutions to be implemented.
• Generating and testing possible solutions – brainstorming, experimental solutions in controlled conditions (Design of experiments – DOE), solutions to avoid error – Poka Yoke, etc., Setting limits and tolerances of new processes.
• Selecting the best solutions using FMEA, House of Quality, etc.
• Establish the plan to achieve Pilot Studies) – resources, risk management, establishing contingency plan, WBS, budget, control plan;
• Control, feedback and correction for each phase of the pilot program, setting the final solution to implement;
Control: Implementation and documentation of proposed solutions; control of the parameters of implemented solutions, continuous generation of improvement solutions.
• Implementation of the proposed solutions in current practice;
• Preparation of documents, standards and procedures.
• Establish control plan to monitor the persistence in using and integrating new solutions.
• Development and implementation of statistical control plan; monitoring process capability where the new solutions have been implemented
• Transfer by the members of the project team to the future user, of the data on implemented solution.
• Documentation by means of indicators of growth of benefits in the entire chain of value stream – Value Stream (profit, costs, quality parameters, etc.
• Complete project documentation, feedback of project team and declaring the project “closed”.
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