Asq Auto Div Lean Six Sigma Webinar

Copyright 2010 RAM Q Universe, Inc.1Ha DaoASQ Automotive Division

Copyright 2010 RAM Q Universe, Inc.2

ASQ Automotive Division is part of the American Society for Quality (ASQ), the

world�s leading authority on quality issues since 1946.

ASQ Automotive Division has more than 3400 members globally. Members include professionals from almost every discipline in the vehicle manufacturing

and supplier business in the automotive, heavy-truck, off-highway, agricultural, industrial and construction

equipment industries.

ASQ Automotive Division

Ha DaoASQ Automotive Division


! VISION! To be the worldwide leader on quality issues related to

the automotive industry.! MISSION

! To provide member value by identifying, communicating, and promoting automotive quality knowledge, professional development and networking opportunities.

! OBJECTIVES:! Increase member value including members that do not

attend conferences or receive e-mails! Be a global provider of automotive quality knowledge and

learning opportunities for advancing individual and organizational performance excellence.

! Engage, grow and retain members through new and improved communities and cutting-edge technologies.

! Develop and sustain a strong Council Leadership to support our members.

ASQ Auto Business Planning 2009-2010



ASQ Auto Business Plan 2009-2010Objectives A Activity Descriptions Measures Goal Owner/Status

1 Joint Meetings with ASQ/SAE/SME Sections Meetings Arranged 4 times a year Dao2 Automotive Excellence Magazine Mail Dates 2 times per year Pratt3 ASQ Auto Annual Awards Event Event Dates 1 time a year Vize4 IT Transformation Project (Website, Database) Project Report Complete by 12/31 Basava5 International Members Outreach Website, E-Mails 4 times a year Hermenitt6 Senior/Fellow Upgrade and Coaching Member Counts 4 times a year Munro

B Activity Descriptions Measures Goal Owner/Status7 Global Basic Quality Workshops (6) Event Dates 6 times a year Odom8 Quality Webinars & Video Interviews (6) Event Dates 6 times a year Dao9 ASQ Auto Annual Paper Symposium Event Dates 1 time a year Shah10 Global Products and Services Number of products 2 times a year Dao11 ASQ Auto Discussion Board Number of posts 12 times a year Maxson12 ASQ Auto Speakers/SME Database Database Updated 4 times a year Denlinger

C Activity Descriptions Measures Goal Owner/Status13 Meeting Minutes, Records, E-Mails, E-Zines Event Dates 12 times a year Katona14 Marketing/Publicity/Promotion/Social Media Event Dates 12 times a year Oldeck15 WCQI Annual Meeting/Exhibit Booth Event Dates 1 time a year Dao16 WCQI Hospitality Suite / Boat Cruise Event Dates 1 time a year Dao17 VOC Surveys, Feedback & Analysis Event Dates 2 times per year Rall18 Engage, Grow and Retain Members Member Counts 12 times a year Zhou

D Activity Descriptions Measures Goal Owner/Status19 Monthly Council Meetings/Networking Meetings Arranged 9 times a year Katona20 Council Members New Roles Training Training Arranged 1 time a year Shah21 Council Members Development & Mentoring Mentoring 2 times a year Dao22 Council Members Succession Planning Succession Plan 2 times per year Shah23 Christmas Dinner Mtg with Council Members Dinner Arranged 1 time a year Dao24 Financial Plan, Reporting, Audit, Records Council Approval 2 times a year Bykaylo

Increase Member

Value

Provide Quality

Knowledge

Engage, Grow and

Retain Members

Develop Strong Council

Leadership



Northport, MI

First ASQ Auto Webinar March 2010

Lean Six Sigma in the Auto Industry

Roderick A. Munro, Ph.D.ASQ Fellow - CQE, CQA, CMQ/OE;Fellow CQI; IRCA QMS Lead AuditorMarch 22, 2010


Webinar Event

� Purpose� To Be Able to Speak Knowledgeably about

Lean Six Sigma in an Automotive Setting and How to Evaluate It�s Effectiveness.

� Objectives� Overview of LSS for Automotive � Discuss Concepts of Effectiveness� Learn at Least One New Fact� Have Some Fun

www.asq.org/auto


Lean Thinking & Six Sigma � 1990 Automotive Rejected

Motorola�s Six Sigma� 1997 First Public Minitab

Courses in Detroit� 1999 Ford Starts SSBB� 2000 GM Starts DFSS� 2001 Chrysler Starts DFSS� Tier One Suppliers

Encouraged to Use SS� 2002 Economy Slowdown� 2008 Automotive Turmoil

� 1900 Fredrick Taylor �Scientific Management

� 1910 Henry Ford Assembly Line � JIT

� 1950�s Taichii Ohno & Shigeo Shingo � TPS

� 1980�s World Class Manufacturing

� 1990 James Womack "The Machine That Changed The World"


Performance Improvementon the Shop Floor - LSS

� What is Lean Six Sigma?� What Should the Plant be Doing?� Getting Started

� Baseline Data� Process Mapping

� Things to Work On


What is Lean Six Sigma - LSS� Lean Six Sigma has

evolved from a number of processes designed to help an organization operator better and to provide higher customer satisfaction and increase profits.

� SPC� TQM/CQI� Process Improvement (PI)� Q101/Targets/Pentastar� Q1 � Supplier Quality� ISO 9001/QS/TS� Malcolm Baldrige� Lean - JIT� DMAIC � DFSS� G8D � 7 Step � 5 Step


What Should the Plant Be Doing

� Identify That Improvement Is Possible� Change Management / Change Agents� Team Building Dynamics� Map Current Processes� Establish Benchmark Measures for Processes� SDCA / PDSA � standardize/do/check/act� Learn About and How To Use Process

Improvement Tools


Getting the Team Started �Follow the LSS Road Map

1. Develop A Flowchart (or Similar Tool) of a Current Significant Process - �As Is� � in Your Plant/Office.

2. Recognize That Variation Exists in Everything You Do - Standardize the Process Throughout the Organization.

3. Develop/Refine Measures of Work for Customer Satisfaction in the Process.

4. Identify What The Customer Wants And Needs -Reduce Variation Around This Target.

5. Develop A �Should Be� or �Preferred State� Process Flow Map.


Follow the LSS Road Map6. Use A Problem-solving Methodology to Plan

Improvements.7. Follow The PDSA Model to Deploy the Improvement.8. Monitor The Process Using Run Charts or Process

Behavior Charts.9. Incorporate New Technology Where Appropriate.10. Update Standard Operating Procedures or Policies and

Lessons Learned.11. Celebrate Successes.12. Repeat The Road Map for ContinualImprovement - PDSA/SDCA.


PI Flow Chart

SelectIssue

Update SystemAnd TrainPersonnel

Look ForOpportunities

ForImprovement

FutureImprovements

Get Organization Concurrence

CreateFlowchart

Ask KeyQuestions

UpdateFlowchart


LSS Model for PI

QMS / EMS


Things to Work On

� Elimination of Waste in the Organization� Standardized Work� Check Sheets � Run Charts� Variation Reduction� Error Reductions� Customer Satisfaction (Internal & External)� Use All Improvement Tools in Your System


Venn Diagram for PI

http://www.asq.org/quality-press/display-item/index.html?item=H1361


� Stock/Inventories Beyond the Absolute Minimum

� Motion of Employees� Waiting� Overuse of Services

Underuse of Services� Processing and Complexity� Transportation or Movement� Defects / Correction of

Problems� Underutilization of People

Potential Waste 7+ & 5S� Sort� Set-in-Order� Shine� Standardize� Sustain


� What is the History/Evolution of Six Sigma, Lean Manufacturing and/or Lean Six Sigma Within Your Organization.

� What is the Fundamental Premise for the Program?

� What Gains Have Been Documented?� Where Does Management Want the

Program to Go?

Performance Improvementon the Shop Floor - Evaluation


JOSEPH M. JURAN

CHANGES CREEP UP ON US WEEK BY WEEK, A LITTLE BIT AT A TIME. OVER A YEAR OR TWO,

THERE ARE 50 OR 100 OF THESE BITS, WHICH AMOUNTS TO QUITE A BIT. THE SKILLS OF THE MEN HAVE NOT NECESSARILY KEPT

PACE, AND WE WAKE UP TO THE EXISTENCE OF A WIDE GAP.

Managerial Breakthrough 1964 page 343


TS 16949:20096.2.2.2 Training

The organization shall establish and maintain documented procedures for identifying training needs and achieving competence of all personnel performing activities affecting (product quality) conformity to product requirements. Personnel performing specific assigned tasks shall be qualified, as required, with particular attention to the satisfaction of customer requirements.

NOTE 1 This applies to all employees having an effect on quality at all levels of the organization.

NOTE 2 An example of the customer-specific requirements is the application of digitized mathematically based data.


History � QS-9000: 1998Training � Element 4.18

The supplier shall establish and maintain documented procedures for identifying training needs and provide for the training of all personnel performing activities affecting quality. Personnel performing specific assigned tasks shall be qualified on the basis of appropriate education, training and/or experience, as required. Appropriate records oftraining shall be maintained (see 4.16).

Training effectiveness shall be periodically reviewed.

NOTE: Training effectives may be practically reviewed by variousmethods, such as pre- and post-testing and audits/appraisals of performance.


Training Effectiveness

� Types of Evaluation: Confirmative �Summative � Formative

� Kirkpatrick: Four (4) Levels� Reaction� Learning� Behavior� Results

� Rice & Munro Evaluation Model (RMEM)


Rice & Munro Evaluation Model (RMEM)

� Follow Kirkpatrick Levels 1 & 2� Management Reviews Kirkpatrick Levels 3

& 4 for Intent� Internal Audit Manager Incorporates

Information From Above Into Internal Audit� QMS and/or EMS Audit Teams� Audit Reports Used by Training Manager to

Evaluation the Training & LSS Process


Effectivenesshttp://en.wikipedia.org/wiki/Effectiveness

Effectiveness means the capability of producing an effect.

In heat transfer, effectiveness is a measure of the performance of a heat exchanger �

In medicine, effectiveness relates to how well a treatment worksin practice...

In management, effectiveness relates to getting the right thingsdone. Peter Drucker reminds us that effectiveness is an important discipline which �can be learned and must be earned.�

In human�computer interaction, effectiveness is defined as �the accuracy and completeness of users� tasks while using a system�.


Lean Six Sigma Effectiveness� Identify all completed projects in the past six

(6) to eighteen (18) months.� What was the task of each project and who

was involved in each project?� What was accomplished by each project?� Develop questions for the internal audit.� Collect answers to questions and analysis the

organization�s program effectiveness.� Review the effectiveness of the Improvement

Program and make adjustments as needed.

P

DS

A


W. EDWARDS DEMING

A SYSTEM OF PROFOUND KNOWLEDGE

� APPRECIATION FOR A SYSTEM� KNOWLEDGE ABOUT VARIATION� THEORY OF KNOWLEDGE� PSYCHOLOGY


Time � The Next Dimension of Quality

Available Work Time

Before Process Improvement

Value AddProductive

Work

Waste

Available Work Time

After Process Improvement

Value AddProductive

Work

Waste

Take wasted time

out of the process

NecessaryWork

IneffectiveWork

http://www.crmlearning.com/time-the-next-dimension-of-quality


Summary

� What is Lean Six Sigma?� What Should Your Organization Be

Doing?� Getting Started

� Baseline Data� Process Mapping

� Things to Work On


What questions do you have?

www.asq.org/auto


RAM Q Universe, Inc.RAM Q Universe, Inc.

Lean Six Sigma in the Auto Industry

Thank You for Your Participation

www.ramquniverse.comwww.rentablackbelt.com

www.coachquality.comwww.coachleansixsigma.com

For the ASQ Automotive Division



ASQ Automotive Division group on LinkedIn

Twitter.com/asqautomotive

ASQ Automotive Division fan page on Facebook

www.asq.org/auto

LinkedIn

Twitter

Facebook

Internet

ASQ Automotive Division


ASQ Automotive DivisionWin a free Six Sigma Book from ASQ Auto

1. Follow @ASQautomotive

2. Post a comment about the Webinar. Must include @ASQautomotiveand #freebook. A random person will be chosen from the entries.

1. Become a fan of the ASQ Automotive Facebook page.

2. Post a comment about the Webinar on the wall. A random person will be chosen from the entries.

Winners will be chosen on March 29th.

2 different ways to win. 1 book will be given away on Twitter and 1 book will be given away on Facebook.


ASQ Automotive Division verification of attendance � ASQ RU

� ASQ Automotive Division�s first Webinar � March 22, 2010� Title: Lean Six Sigma in the Auto Industry� Presenter: Roderick A. Munro� Electronic Division Meeting: one hour � RU = 0.3 / rewarded under Section E: Meetings

Asq Auto Div Lean Six Sigma Webinar

Automotive

quality asq

ram q universe

year prattincrease3

asq automotive divisionha

automotive setting

asq auto webinar

ezines event dates12

year shah quality