【文章內(nèi)容簡(jiǎn)介】 ? Time Lines, Milestones, and Gantt Charting ? Pareto Analysis ? Belbin Analysis ? Value Stream Mapping ? Value of Speed (Process Cycle Efficiency / Little’s Law) ? Operational Definitions ? Data Collection Plan ? Statistical Sampling ? Measurement System Analysis (MSA) ? Gage Ramp。R ? Kappa Studies ? Control Charts ? Histograms ? Normality Test ? Process Capability Analysis ? Process Constraint ID and Takt Time Analysis ? Cause and Effect Analysis ? FMEA ? Hypothesis Tests/Conf. Intervals ? Simple and Multiple Regression ? ANOVA ? Components of Variation ? Conquering Product and Process Complexity ? Queuing Theory ? Replenishment Pull/Kanban ? Stocking Strategy ? Process Flow Improvement ? Process Balancing ? Analytical Batch Sizing ? Total Productive Maintenance ? Design of Experiments (DOE) ? Solution Selection Matrix ? Piloting and Simulation ? MistakeProofing/ Zero Defects ? Standard Operating Procedures (SOP’s) ? Process Control Plans ? Visual Process Control Tools ? Statistical Process Controls (SPC) ? Solution Replication ? Project Transition Model ? Team Feedback Session ? Value Stream Map for Deeper Understanding and Focus ? Identify Key Input, Process and Output Metrics ? Develop Operational Definitions ? Develop Data Collection Plan ? Validate Measurement System ? Collect Baseline Data ? Determine Process Capability ? Complete Measure Gate Tools Activities Kaizen, 5S, NVA Analysis, Generic Pull Systems, Four Step Rapid Setup Method Identify and Implement Quick Improvements Improve Analyze Control Measure Define page 11 Lean 6 sigam introduction Applying the Tools for Results Distribution L ean Si x Si g m a R ed u ces Pr o cess C ycl e T i m e, I m p r o vi n gOn T i m e D el i ver y Per fo r m an ce fo r T i er On e A u to Su p p l i er ( Av e rage Re duce d fro m 14 Day s to 2 Da y s, V aria nce from 2 D ay s to 4 Ho urs)0%10%20%30%40%50%60%70%80%90%0 2 4 6 8 10 12 14 16 18 20L e a d T i m e t o C u s t o m e r ( d a y s )% DistributionM e a n D e l i v e r y T i m e R e d u c e dT i m e V a r i a t i o n R e d u c e dReduce Variation Shift the Mean page 12 Lean 6 sigam introduction Lean Six Sigma Is the Integration of Two Powerful Business Improvement Approaches... ? Lean ? Value stream mapping to identify Non Value Add Cost ? Time Trap id and removal ? “Pull” from the Customer ? Setup and queue reduction ? Process flow improvement ? Total Productive Maintenance ? 5S Foundations ? Kaizen for rapid improvement…. ? Six Sigma ? Management Engagement ? Dedicated Infrastructure/People ? Voice of the Customer ? Statistical process control ? Design of Experiment ? PokaYoke ? Gage Ramp。R ? Failure Modes Effect Analysis ? Cause and Effect Analysis…. Culture+Quality+Customer Speed+Low Cost+Flexibility Six Sigma Quality Enables Lean Speed (Fewer Defects Mean Less Time Spent on Rework) Lean Speed Enables Six Sigma Quality (Faster Cycles of Experimentation/learning) page 13 Lean 6 sigam introduction Six Sigma Improves Quality of Value Add Steps Six Sigma Improves Quality, Lean Eliminates NonValueAdd Steps in the Value Stream – Both Are Required to Reduce the Cost of Process Complexity of Steps 177。 3? 177。 4? 177。 5? 177。 6? 1 % % % 7 10 20 40 Overall Yield vs. Sigma (Distribution Shifted 177。 ?) Source: Six Sigma Research Institute, Motorola University, Motorola, Inc. Lean Reduces NonValued Add Steps page 14 Lean 6 sigam introduction The Lean Six Sigma Secret The principal Lean Six Sigma insight is that: ? Material spends 95% of its time waiting, creating overhead cost ? 80% of the wait time is due to Time Traps caused by 20% of the activities ? They can be found using Time Trap analysis. ? Time Traps can be eliminated using Lean and Six Sigma tools. ? Lead time and WIP+ Finished Goods inventory can be reduced 5080% ? Overhead+Quality Cost can be reduced by 20% These insights hold true for all processes Raw Materials Production Process 8 Week Total Cycle Time Product Order Before Improvements 40 Days 10 Days Cycle Time Reduction 75% Reduction After page 15 Lean 6 sigam introduction Project Selection Reduces Number of Projects and Provides Focus Effort Economic Value High Low Med Hig h