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Six Sigma – Yellow Belt Certification

1

Introduction to Lean

Lean Manufacturing
• Lean Manufacturing a
...
a
...
(2008, September 28th)
...

Retrieved October 3rd, 2010, from
World Auto News & Reviews:
http://allworldcars
...
,
•

The principles of lean production include
–
–
–
–

•

Efficient use of resources and elimination of waste
Teamwork
Communication
Continuous improvement

Lean production vs
...
What the Customer / Consumer is willing
to pay for
•
...

– Indicates an unbalanced production line

Muda of Overproduction
• Definition:
Producing more parts than necessary or
producing parts at a faster-than-required rate

• Result:
Builds unnecessary inventory Indicates more
capacity than is necessary

Muda of Correction/ Rework
• Definition: Reprocessing, Repairing or reworking
defects

• Result: Higher costs of materials, equipment,
floor space & labor
...


Muda of Motion
• Definition:
Movements of people or machinery which do
not contribute added value to the product

• Result:
– Increases the risk of damage to the product
– Increases the labor required

Muda of Processing
• Definition:
Unnecessary work that has no connection
with advancing the line or improving the
quality of the product

• Result:
Adds unnecessary expense in materials,
labor, equipment capacity, floor space, etc
...

– All inventory is muda
...
Defectives
hidden
in finished goods inventory hides other inefficiencies:
excessive downtime, poor production planning,
operator inconsistencies, etc
...
Conveyance is in
incidental required action
...
Adds risk of defects
due to wrong moves, dropped product, etc
...
Defectives

What is a defective?

What is a defect?

Defects vs
...
4 defects per million opportunities
...
9997%

A Six Sigma defect
is defined as anything outside of customer specifications
...


Six Sigma is a customer centric
data-driven methodology
for eliminating defects in any process – from manufacturing to transactional
and from product to service
...


DMAIC methodology
Problem
FACTORS :(A , B , C

Define

Measure

, D , E , F , G , H , I , J , K , L , M , N ,O , P , Q , R , S , T , U , V , W , X , Y , Z )

By Scoping derive the specific problem , Construct Problem
statement , Construct Objective statement
(A , D , E , F , G , H , I , J , K , L , M , N , Q , R , S , T , U , V , W , X ,
Y,Z)
Process Mapping , SIPOC Analysis , Cause and Effect
Matrix , FMEA , Repeatability and Reproducibility
(A , D , E , J , K , L , M , N , Q , S , T , U , V , W , Z )

Analyze

Understanding the best Graphical
Analysis , Hypothesis Testing
(A , D , L , T , V , Z )

Improve

Design Of Experiments
(A , T , V , Z )

Control

Control Charts ,
Mistake proofing

The Best Solution

Jeff Immelt, CEO - GE

 "WE WANT TO BE A COMPANY THAT
IS ALWAYS GETTING BETTER
...
"

GE – General Electric

GE – General Electric

About GE
GE works on things that matter
...

Finding solutions in energy, health and home, transportation
and finance
...

Not just imagining
...
GE works
...

We must delight our customers and
relentlessly look for new ways to exceed
their expectations
...
7
65
...
8
86
...
1
93
...
1
98
...
4
100
...
What the Customer / Consumer is willing
to pay for
•
...
g
...
Cross multiplication of Input values and
Output values
2
...

• to evaluate risk management priorities for mitigating
known threat vulnerabilities
...


History
• formally introduced in the late 1940s for military usage
by the US Armed Forces
• it was used for aerospace/rocket development to avoid
errors in small sample sizes of costly rocket technology
...
The
primary push came during the 1960s, while developing
the means to put a man on the moon and return him
safely to earth
...


The Pinto Scandal…
...
Ford Motor Co
...


The Pinto Scandal…
...
Critics argued that
the vehicle's lack of a true rear bumper as well as any
reinforcing structure between the rear panel and the tank,
meant that in certain collisions, the tank would be thrust
forward into the differential, which had a number of
protruding bolts that could puncture the tank
...


Process Function

The highest value process steps
from the C&E matrix
...

design intent?

Potential Failure
Process Function
Potential Effects
Mode

The highest value
process steps from
the C&E matrix
...


Process
Function

Potential
Failure Mode

In what ways
The highest might the
value process process
potentially fail
steps from the to meet the
C&E matrix
...

the process
requirement
s and/or
design
intent?

Potential
Effects
What is the
effect of
each failure
mode on
the outputs
and/or
customer
requirement
s?

S
(severity
rating)
How Severe
is the effect
to the
customer?

0 – Lowest
10 - Highest

Potential
Cause(s)
Describe in
terms of
something
that can be
corrected or
controlled
...

Try identify
the causes
that directly
impacts the
failure mode,
i
...
, root
causes
...


Potential
Failure Mode

Potential
Effects

In what
ways might
the process
potentially
fail to meet
the process
requirement
s and/or
design
intent?

What is the
effect of
each failure
mode on the
outputs
and/or
customer
requirement
s?

S
(severity
rating)
How Severe
is the effect
to the
customer?

0 – Lowest
10 Highest

Potential
Cause (s)
Describe in
terms of
something
that can be
corrected or
controlled
...
e
...


O (occurrence
rating)
How often
does the
cause or
failure mode
occur?
0 – Lowest
10 Highest

Process
Function

The highest
value
process
steps from
the C&E
matrix
...

i
...
, root
causes
...


Potential
Failure
Mode
In what
ways
might the
process
potentially
fail to
meet the
process
requireme
nts and/or
design
intent?

Potential
Effects
What is
the effect
of each
failure
mode on
the
outputs
and/or
customer
requireme
nts?

S
(severity
rating)

O
Current
Potential (occurrence
Process
Cause(s)
rating)
Controls

D
(detection
rating)

How
Severe is
the effect
to the
customer
?

Describe
in terms
of
something
that can
be
corrected
or
controlled
...
e
...


How well
can you
detect
cause or
Failure
Mode?

0–
Lowest
10 Highest

How often
does the
cause or
failure
mode
occur?

What are
the
existing
controls
and
procedure
s ,that
either
prevent
failure
mode
from
occurring
or detect
the failure
should it
occur?

10 - Lowest
0 - Highest

S
O
D
Potential
Current
RPN (risk
Process
Potential (severity Potential (occurren
(detection
Failure
Process
priority
Function
Effects
rating) Cause(s) ce rating)
rating)
Mode
Controls
number)
In what
ways
might
the
process
potential
ly fail to
meet the
process
requirem
ents
and/or
design
intent?

What is
the
effect of
each
failure
mode on
the
outputs
and/or
custome
r
requirem
ents?

How
Severe
is the
effect to
the
custome
r?
0–
Lowest
10 Highest

Describe
in terms
of
somethi
ng that
can be
correcte
d or
controlle
d
...
e
...


How
often
does the
cause or
failure
mode
occur?
0–
Lowest
10 Highest

What
are the
existing
controls
and
procedur
es ,that
either
prevent
failure
mode
from
occurrin
g or
detect
the
failure
should it
occur?

How
well can
you
detect
cause or
Failure
Mode?

10 Lowest
0 Highest

SxOxD

The
highest
value
process
steps from
the C&E
matrix
...
Defects

Error Condition Vs
...

capability improved?
improving
Include the
?
detection, or for
implementation
identifying the root
date for any
cause if it is
changes
...


R
P
N

Recomputed
RPN after
actions are
complete

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