introduction to Lean Six Sigma video note

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19:57 2013-7-26 Saturday
introduction to Lean Six Sigma method,
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5s lean tool
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continuous improvement
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Ford: interchangable parts
Toyota:
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Lean arises from the Japanese auto industry
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craft -> mass production -> Lean thinking
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inspection does not take all the earth
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mass production: focus on product
lean: focus on customer
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six sigma was developed by Motorola
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deliver value to customer,
reduce waste
flow focused
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sigma -> standard deviation in statistics
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Lean Six Sigma
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5S: a simple lean tool
sort,
straighten,
scrub,
standardize,
sustain
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Sort
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Straighten == Set in Order
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Scrub == Cleaning
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process innovation
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Boing, Airbus
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cost-price relationship
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cost + profit == price -> customer-determined price
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industry must lower cost to achieve profit!
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Aerospace industry
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red, yellow, green zone
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enterprise
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end user
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product support // 2/3 life cycle cost
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core enterprise,
extended enterprise
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supply chain
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multi-program enterprise
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stakeholders:
any group or individuals who
can affect or is affected by the achievements of
the organization's objective.
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stakeholders <-> shareholders
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value
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LeanEnterprise Value, mit
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life cycle process
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enterprise process
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deliver value to the customer
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lean applies to all enterprise process
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enterprise value creation
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Kanban - a Lean tool
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Lean is a "Journey" not a "State"
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TPS == Toyota Producton System
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Lean thinking
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start Lean Six Sigma video 1-02
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COO == Chief O... Officer
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process <-> end state
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What's Rolls Royce's stakeholders?
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customers
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vision
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streamlined & value-adding activity
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team & leadership skills
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knowledge-based belts: yellow, green, black
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teach people how to work in teams
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Sensi
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Essential tools for Business improvement:
1. Define
2. Measure
3. Analyze
4. Improve
5. Control
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ASQ == American Society of Quality
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metrics
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shareholder issues
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inventory turn
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best practices
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breaking down the barriers
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start ses 1-4 lean thinking
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Process
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external customer
internal customer
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process map
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only understood process can be improved
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main process flow
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Hot Dog Stand
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understanding & improving process
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process improvement
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5 Lean thinking fundamentals:
1. value
2. value stream // eliminate waste
3. flow
4. pull // customer pull
5. perfection
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value added activity
non-value added activity -- necessary waste
non-value added activity -- pure waste
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deliver value to customer
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value stream
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What moves in a value stream?
1. material flow
2. information flow
3. people flow
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Flow
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Time:
wait time,
processing time
cycle time,
customer demand / lead time
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Wait Time
WIP == Work In Process, (Queue Time, Delay Time)
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VAT == Value Added Time
NVAT == Non Value Added Time
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cycle time // boundary of your process time
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POU == Point Of Use
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What is a Pull System?
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downstream
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pull system
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lead time
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push system <-> pull system
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pull system: Dell computer
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Takt Time: // drum beat
measure of customer demand
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balanced work
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standard work
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single piece flow <-> batch & queue
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inventory level
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move downstream
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Kanban: visual cuing system
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visual control
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Andon: a specific visual control device
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team leader
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production line
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pursuing perfection
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root cause
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5 whys? // to find root cause