LEAN Six Sigma LEAN Six Sigma Introducing the basics of LEAN and Six Sigma and applying the techniques in design work
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LEAN Six Sigma
LEAN Six Sigma Introducing the basics of LEAN and
Six Sigma and applying the techniques in design work
Objectives - Education
What is LEAN Six Sigma in 3 presentations. First presentation to give a general
information about LEAN and Six Sigma, about quality control, processes, some statistical and mathematical explanation.
Objectives - Education
Second presentation will explain what is LEAN - how to save money by using simple techniques like 5S and Value stream map and as example will be presented system for organising electronic components - creating data base, organasing storage area, make design kits.
Third presentation will be focused on Six Sigma – DMAIC, cause and efect analysis, some statistical tools for presenting the data.
LEAN and Six Sigma
What is LEAN
What is LEAN
The Seven Wastes
What is LEAN
What is LEAN
What is LEAN Production
What is LEAN Production
LEAN Production Producing only what is needed, when it is needed
Pull System - A system of cascading production and delivery instructions from downstream to upstream activities in which nothing is produced by the upstream supplier until the downstream signals a need,
TaktTime - Balance, Predictable Cycle TimeEliminate all wasteValue Steam Value Add – Non-Value AddReducing parts staying in “Work in Progress” stateOne-piece flow or controlled/small batch sizes
PULL vs PUSH system
What is LEAN Production
LEAN Production Benefits– Major productivity increases– Reduction in throughput times– Reduction in inventory– Improved quality– Reduced time to market
How much does it cost?– In many cases, companies replace expensive
equipment with much simpler and cheaper equipment.
– LEAN production does not emphasize technology or automation.
What is LEAN
Tools of LEAN - Competitive Excellence
Visual Factory 5STotal Productive MaintenanceQuality Control Process ChartingProcess CertificationMistake Proofing (POKA-YOKE)Set-up ReductionStandard WorkValue Stream Mapping
Visual Management
Visual Management
Visual Management
What is Value Stream Mapping ?
Value Stream Defined•The specific activities required to design, order, and provide a specific product, from concept to launch, order-to-delivery, and raw material to finished item in the hands of the customer.
Each step in the value stream is either: 1.Creating value 2.Creating no value, but unavoidable due to
current technologies and production assets 3.Creating no value and immediately avoidable
What is Value Stream Mapping ?
What is Value Stream Mapping ?
Value add ActivityThat which the customer will pay for.
Work done right the first time.
Non-Value Add or Waste Process/operation that takes time and resources but do not add value to the product or service.
What is Value Stream Mapping ?
What is Value Stream Mapping ?
Purpose of Value Stream Mapping / AnalysisArrive at a common understanding of the current process
The relationship of process steps The relationship of material and information flows А true picture of the process
Define the baseline to measure improvements against Recognize that lots of waste exists �Define a vision of the future process (12 month outlook) Identify opportunities for improvement and establish
common leadership objectives Design an implementation plan for process improvements
Quick fixes Projects
What is Value Stream Mapping ?
KAIZEN
KAIZEN
Simply put, Kaizen is “Continuous Improvement”, derived from the Chinese , but also used by the Japanese to explain a gradual and orderly continuous improvement for anything.
Pioneered by the Toyota Motors Corporation: Taiichi Ohnoalong with Shigeo Shingo further developed and structured Kaizen versions at Toyota.
Kaizen is a effective tool for driving continuous improvement activities, and it doesn’t cost lots.
Kaizen is about driving lots of small incremental improvements on a regular basis.
It takes dedicated work and commitment Benefits occur over time
Shows bottom line results - A benefit to both Profitability and Quality
KAIZEN
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
Standardize the work place to prevent disorder, chaos, disorganization, and unclean conditions.
Should leave no doubts about how something is done, who does it, and when it happens – keep records...Document changes and share information with others.
What are the objectives?Ensure quality products at the source.Prevent problems beforethey arise.
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
5S - Sort, Simplify, Shine, Standardize, Sustain
5S in BENETEL
5S – How to make our life easyer?Creating the component data base:
- new part number system – with field for:The type of component, The value, Parameters, Manifacture part numbers (MURATA,
Johanson, Coilcraft...)Place – where stay in the rack
- storage area- designers kits – with most frequently used
components like resistors, capacitors, inductors
5S – for components
Design kits
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