Lean 6 sigma

This ppt will help you learn about lean six sigma.

1. An Introduction to Lean Six Sigma (6 σ ) Submitted By Raju Malani Technical learning academy

2. Content

3. 1. What is Six Sigma? Sigma ( σ ) is a statistical concept that represents how much variation there is in a process relative to customer specifications. Sigma Value is based on “defects per million opportunities” (DPMO). Six Sigma (6 σ ) is equivalent to 3.4 DPMO. The variation in the process is so small that the resulting products and services are 99.99966% defect free. Target Customer Specification After 1 s 3 s 6 s 6 s ! By reducing the variability, we improve the process Target Customer Specification After 1 s 1 s 3 s 3 s 6 s 6 s 6 s ! No Defects! By reducing the variability, Target defects defects Customer Specification Customer Specification

4. 2. What is Lean? The methodology of increasing the speed of production by eliminating process steps which do not add value T hose which delay the product or service T hose which deal with the waste and rework of defects along the way Core Ideas of Lean Determine and create value What does the customer want? Use “pull” instead of “push” systems to avoid overproduction Inventories hide problems and efficiencies. One piece flow Make the work “flow,” so that there are no interruptions and no wasted time or material Eliminate the seven speed bumps (non-value adds) caused by waste Use the “five whys?” and Six Sigma problem solving to eliminate defects

5. 3. What is Lean Six Sigma? 6 σ 6 σ Lean Six Sigma Lean Six Sigma Use the PDCA Method and tools like 8 wastes and 5S to achieve to achieve continuous improvement Use the DMAIC and tools like control chart and FMEA to achieve continuous improvement Leverages the problem solving methods to help organization achieve their mission and customer satisfaction Lean Six Sigma is a systematic approach to reduce or eliminate activities that do not add value to the process. It highlights removing wasteful steps in a process and taking the only value added steps. The lean six sigma method ensures high quality and customer satisfaction in the manufacturing. 

6. 4. Adopted the 7 (Seven) speed bumps of lean Non-value added waste – is any activity which absorbs money, time, and people but creates no value.

7. 5. Benefits of Lean Six Sigma The general improvement in efficiency, though, is only one aspect of Lean Six Sigma. Other than improving the company bottom line, there are several other potential benefits

8. 6. Six Sigma toolbox Analysis of Variance (ANOVA) Box Plots Brainstorming Cause-effect Diagrams Correlation & Regression Design Of Experiments Graphs and Charts Histograms Hypothesis Testing Pareto Analysis Process Capability Studies Process Control Plans Process Flow Diagrams Quality Function Deployment Response Surface Methods Scatter Diagrams Standard Operating Procedures (SOPs) Statistical Process Control

9. 7. Methodology Some of the most popular ones are… 1. Kaizen 2. DMAIC 3. Value Stream Mapping 4. Kanban 5. Business Process Mapping (We will understand DMAIC)

10. 8. Challenges during implementation of lean six sigma

11. 8. Challenges during implementation of 5S

12. 9. Result of case study Lean Six Sigma in the Energy Service Sector: A Case Study ( Call Center case study) Lean Six Sigma approach uses the problem-solving methodology DMAIC: 1 . Define - in this step the team is formed, the Project Charter is developed, the Costumers’ voice is analyzed, a process map is created; 2 . Measure - the actual performance is measured ; 3. Analyze- the results of measurements, determining the causes of process imperfections and possible solutions for them . 4 . Improve - the team generates and selects a set of solutions to improve sigma performance. 5 . Control – ensuring that improvement sustains over time. As a result of the Lean Six Sigma implementation, the company significantly improved the actualization rate from 2.6% to 20%, outperforming the 10% target in just 3 months, updated the internal procedures, identified the main issue of the calls and improved the overall process.

13. 10. Conclusion and future implementation plan Conclusion Catching mistakes and errors is important before they turn into defects. Lean Six Sigma is often used in production as a method of improvement. Through this study we demonstrated its applicability in a service activity for the energy sector. Future Implementation plan Now the company will work on optimizing the bill issue in order to decrease the dials in the call center . Later on company will work on quantity and quality in every aspects of the call center.

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