Lean Six SigmaComprehensive Implementation Model

Charter, VOC,VSM, SIPOC, CTQ, Scorecards

Brainstorming, MSA, Walkthrough, C&E, 5S, KPOV and KPIVs, RTY, Benchmarking

Fishbone Diagrams, Pareto Charts, Control Charts, Process Capability, FMEA, Statistical Analyses, Layout and Process Flow Analyses

Kaizen Event, Contingency Planning, Pilot, DOE, Optimization

Standardize Process, Training, Visual Aids, Mistake Proofing, Document Benefits

TOOLS PROCESS ANALYTICS TECHNOLOGY

Def

ine

Mea

sure

Ana

lyze

Imp

rove

Con

trol

Business Intelligence

Decision Support Systems

Dashboards

Performance Management Systems

Roadmap for Lean Six Sigma

1. Lean 2. Design for Six Sigma 3. Core Six Sigma

Define Define Define

Measure Measure Measure

Analyze Analyze Analyze

Streamline Design Improve

Standardize Verify Control

Waste Reduction New Product/Service Improve Quality

Efficiency Design New Processes Improve Processes

Speed Improve Competitiveness Reduce Defects

Increasing Emphasis on Analytics

Deployment

Define Phase

• Project Charter – Create problem statement and estimate project benefits– Gain consensus on project scope and stakeholders– Identify needed resources

• Voice of the Customer (VOC)– Identify Critical to Quality (CTQ) Issues (customer and process)

• Process Maps– Use Value Stream Mapping to outline broad process– Use SIPOC to establish context– Use detailed flowcharts to map process

• Scorecards– Identify Fundamental (overall) objective and possible metric (Big Y)– Identify specific “means” objectives and metrics (small ys)– Describe “multidimensional” performance assessment of process

Measure Phase

• Brain Storming / Interviewing for Operational Definitions

• Measurement Systems Analysis

• Process Walkthrough for Line Balancing

• Identify each KPOV and corresponding KPIV

• Tabulate Causes (KPIV) and Effects (KPOV) in a Cause and Effect Matrix

• Identify and evaluate metrics for each output and input variables

• Outline Data Collection Strategies

• Implement the 5S Methodology to address above issues

• Benchmark processes in other organizations

Analyze Phase

• Process Analysis– Calculate Process Capability (Cpk)) and Rolled Throughput Yield (RTY)– Analyze Layout and Process Flow

• Graphical Modeling– Use Fishbone diagram to map causes and effects

• Root Cause/Statistical Analysis– Brainstorm to prioritize inputs– Use Charts and Descriptive Statistics to evaluate each output and inputs– Use Pareto Charts– Use Correlation Analysis

• Cause and Effect Modeling– Use Influence Diagrams to map relationships between inputs, process outcomes, and overall performance

metrics– Use time-series and regression modeling to estimate relationships

• Simulate Models and Identify Process Improvement Strategies– Develop and Use Decision Support Systems– Evaluate potential scenarios – Evaluate performance implications of various strategies

Improve Phase

• Conduct a “Kaizen” event to develop an implementation plan– Empower stakeholders to create “future state” and outline benefits– Identify potential obstacles and resolve them– Implement feasible changes immediately

• Pilot test improved process– Simulate potential strategies– Test various assumptions – Design experiments and gather data

• Implement Improved process and technology– Implement Decision Support Systems for continuous improvement– Provide analytical support for continuous evaluation of process– Utilize new technology– Create contingency plans

Control Phase

• Standardize– Document the new process– Create Standard Operating Procedures (SOPs)

• Create and deliver training– Orientation to all employees– Just-in-time to new teams

• Post visual aids to reinforce new process

• Obtain final approval of documented project benefits

• Identify process owner

• Utilize control charts to continue to monitor process– Implement a Process Management Control System (PMCS)