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How long with YESCO?Job Title?Something that nobody else knows
about you?
What are your expectations of the class?
LT6 Defined
L stands for Lean T stands for Theory of Constraints 6 stands for 6-Sigma
LT6 Defined|
LT6 Certification Program
A program designed to teach through instruction and Hands On participation the following principles and tools: Systematic method focused on Identifying and Eliminating Waste Processes centered around Value Added Activities A culture in which all employees participate Tools that can be applied to all aspects of the business Including many developed proven tools
The LT6 Certification is a self paced training Program
LT6 Defined|
LT6 Certification Program
Most of us consciously do improvement activities at work, we are trying to improve our environment by focusing on problem and eliminating areas that are not valuable to us or the company (waste). LT6 is designed to help us be most effective at this.
LT6 Defined|
LT6 Certification Program
LT6 Defined|
LT6 Certification Program
4 Levels (belts) Required Training Elective Training Participation in Events Some Reading Train others Mentor others
Must First Understand WASTE
Simply put Waste is defined as Non-Value Added activity
Non-Value Added activity consumes resources but does add value to the product or service
Waste|
LT6 Certification Program
There are 8: Defects Overproduction Waiting Non-utilized talent Transportation Inventory Motion Extra processing
Waste|
LT6 Certification Program
Oh Yea, one more important form of Accidents!
Waste| Value Add?
LT6 Certification Program
Sometimes due to limitations, Non-Value Added activity is necessary
To be considered Value Added, a process must ….
A. Physically Transform the Product,B. In a way the customer wants, and C. Be done right the first time.
3 DISCIPLINES
3 DISCIPLINES|
LT6 Certification Program
These 3 disciplines constitute the Continuous Improvement
Program at YESCO!
LEANTheory of Constraints
6 Sigma
LT6 Certification Program
6 Sigma ()
LT6 Certification Program
LEAN| 6
Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and variation in manufacturing and business processes.
It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization ("Black Belts" etc.) who are experts in these methods.
Each Six Sigma project carried out within an organization follows a defined sequence of steps and has quantified financial targets (cost reduction or profit increase).
LT6 Certification Program
LEAN| 6
LT6 Certification Program
LEAN| 6
ProcessProcessProcessProcess Key Key Process Process OutputsOutputs
Key Key Process Process OutputsOutputs
Noise InputsNoise Inputs
(Discrete)(Discrete)
Noise InputsNoise Inputs
(Discrete)(Discrete)
Examples•Different
Operators•Different Machines•Different Shifts
Noise InputsNoise Inputs
(Continuous)(Continuous)
Noise InputsNoise Inputs
(Continuous)(Continuous)
Examples•Room Temperature•Barometric Pressure•Relative Humidity•Raw Material
Characteristics
Examples•Temperature•Pressure•Time
ControllablControllable Inputse Inputs
ControllablControllable Inputse Inputs
Tools• Scatterplots• Correlation• Regression
Tools• Scatterplots• Correlation• Regression
Tools• Boxplots• Main Effects and
Interaction Plots• ANOVAs, T-test
Tools• Boxplots• Main Effects and
Interaction Plots• ANOVAs, T-test
Tools• C&E Matrix• FMEA• Fishbone• Short-term
Capability
Tools• C&E Matrix• FMEA• Fishbone• Short-term
Capability
LT6 Certification Program
LEAN| 6
Being able to “sustain your gains” and set controls in place that will help achieve that
What controls do we have in place? Safety Program Training Measuring Incentives Etc.
LT6 Certification Program
Theory Of Constraints
LT6 Certification Program
THEORY OF CONSTRAINTS|
A management philosophy that focuses the resources of an organization on improving the performance of the constraint that directly affects throughput
the output of any system consists of a series of steps where the output of one step depends on the output of one or more previous steps will be limited, or constrained, by the least productive steps.
LEAN
LEAN|
LT6 Certification Program
A systematic approach to identifying and eliminating waste
by flowing the product at the pull of the customer in pursuit of perfection.
LEAN|
LT6 Certification Program
A systematic approach to identifying and eliminating waste
by flowing the product at the pull of the customer in pursuit of perfection.
LEAN|
LT6 Certification Program
LEAN| Building Blocks – VALUE STREAMAPPING
LT6 Certification Program
Defining exactly what a process is, who is responsible and what should be completed.
Visually showing the steps in a Is used to analyze & document a processCan be used in trainingIs helpful in identifying waste in the Value
Stream.
May need to use a PQR to identify Value Streams
LT6 Certification Program
Shows processes, and those shared by various value streams
LEAN| Building Blocks – VALUE STREAMAPPING
LT6 Certification Program
LEAN| Building Blocks – VALUE STREAMAPPING
LT6 Certification Program
LEAN| Building Blocks – VALUE STREAMAPPING
LT6 Certification Program
LEAN| Building Blocks – 5S
LT6 Certification Program
LEAN| Building Blocks – 5S
LT6 Certification Program
LEAN| Building Blocks – 5S
“A place for everything and everything has a place”
Cleanliness and Order 5S stands for: Sort, Scrub, Secure
Safety, Select Locations, Set Locations and Bonus +1…Sustain
Is preparatory to Visual Workplace
LT6 Certification Program
LEAN| Building Blocks – VISUAL WORKPLACE
Makes answers readily and visually available to anyone who needs them anytime, and as close to the point-of-use as possible
“What do I need to know” and “What do I need to Share”Automatic RecoilOne Point LessonsActions Item and Suggestion BoardsErgonomics
LT6 Certification Program
LEAN| Building Blocks – VISUAL WORKPLACE
LT6 Certification Program
LEAN| Building Blocks – VISUAL WORKPLACE
LT6 Certification Program
LEAN| Building Blocks – VISUAL WORKPLACE
LT6 Certification Program
LEAN| Building Blocks – VISUAL WORKPLACE
LT6 Certification Program
LEAN| Building Blocks – TPM
Systematic approach to the elimination of the six major equipment losses:
1. Setup 2. Adjustment3. Breakdowns4. Idling and minor stoppages5. Reduced Speed6. Startup7. Defects and Rework
LT6 Certification Program
LEAN| Building Blocks – TPM
TPM is accomplished through various tools, such as:
SMED Preventive Maintenance Corrective Maintenance Predictive Maintenance Integrating equipment operators
into “Clean to Inspect, Inspect to Clean”
LT6 Certification Program
LEAN| Building Blocks – Pull / Kanban
Japanese for “signboard or billboard” also, Kan means “visual” and Ban means “card or board”
Is a signaling system to trigger action Kanban scheduling systems operate like supermarkets. A
small stock of every item sits in a dedicated location with a fixed space allocation. Customers come to the store and visually select items. A signal is triggered to replenish the item.
Kanban (signals) can be to MOVE something or to BUILD something.
LT6 Certification Program
LEAN| Building Blocks – Pull & Kanban
LT6 Certification Program
LEAN| Building Blocks – POUS
A place to store common non-inventoried parts (production supplies)
Usually filled by a vendor or someone in the facility (water spider?)
LT6 Certification Program
LEAN| Building Blocks – Std Work
Analyzing a process in great detail Evaluating which steps are Value Added,
remove if possible Non-Value Added Standardizing the remaining steps in the
process (Std Work) Teach and train Audit to Sustain improvements Review often for opportunities to improve
LT6 Certification Program
LEAN| Building Blocks – Teams
Team Improvement Activity10 people’s ideas are better than one
Should be done on a regular basis Usually a 1 to 5 day event focused on
medium sized problems, focused on real change.
LT6 Certification Program
LEAN| Building Blocks – Teams
The goal is to eliminate waste Kaizen Team is a group of individuals
focused on a specific improvement activity.
Kaizen Teams may use any of the Lean tools available
Formal way to collaborate with coworkers A3’s are the standard reporting tool
LT6 Certification Program
LEAN| Building Blocks – Teams
Should follow the “Scientific Method” (PDCA) or Plan, Do, Check and Act
Encourages accuracy and completeness A method to lead oneself through the
PDCA cycle on all improvement efforts and record for review and future reference
A3 represents the size of the paper (11 X 17)
LT6 Certification Program
LEAN| Building Blocks – Teams
Often the most missed step Various tools to help get to the Root
Cause5 Whys – ask the question “why” at least
five times, until arriving at the root causeFishbone DiagramPareto AnalysisStatistics
LT6 Certification Program
LEAN| Building Blocks – Quality at the Source
Inspection at any point in a product’s life (as it is being produced)
Implementation of error-proofing (Poka-Yoke) in machine and manufacturing processes
Immediate feedback to shorten the time for corrective action
LT6 Certification Program
LEAN| Building Blocks – Batch Reduction
Helps with the following: One piece flow - Pull Just in time Inventory (WIP) reduction Increases agility in responding to pull
signals
LT6 Certification Program
LEAN| Building Blocks – Cellular/Flow
Benefits: Efficient flow-through manufacturing system Eliminates waste Minimizes WIP Optimizes floor space Reduces lead time – improves customer response
time Reduces costs and increases capacity Improves Communication Improves Quality
LT6 Certification Program
LEAN| Building Blocks – Cellular/Flow
Multi functional processing VS departmentalized
Cross trained operators function as a team Product is “pulled” from one operator to
the next Limited or No inventory between operators Operators “float to the bottleneck”
LT6 Certification Program
LEAN| Building Blocks – Cellular/Flow
LT6 Certification Program
LEAN| Building Blocks – Plant Layout
Benefits: Reduced
transportation and handling waste
LT6 Certification Program
Summary
LT6 Certification Program
Summary|
We should follow a continuous improvement methodology
Remember… “everything is a process, every process can be improved”
Talk to your in house Lean Specialist, start attending training sessions, start participating in Kaizen Events, get certified
Enjoy the Journey A few more things to keep in
mind……..
LT6 Certification Program
Summary|
Is a listening process which will help us understand the needs of those we serve
Is active and critical listeningOne on one interviewsSuggestion BoxesSurveysObservationsEncouraging Input and Participation
LT6 Certification Program
Summary|
Don’t just analyze from your office Safety Audits Monthly Safety Tours Random observations Daily “report out meetings” (Std Work
for Leaders)
LT6 Certification Program
Summary|
Critical element in Continuous Improvement Program
“You can’t improve what you don’t measure”Baseline DataGoals
Data helps your control Plan Bottom line benefits (easy to track)
LT6 Certification Program
End of Session
Questions??