Lean Six Sigma - Segla International

Overview of Lean Six Sigma

Segla International
• A key goal of Segla is to provide our clients with complete:
“Business Efficiency Solutions”
• We are a niche training and consulting organisation that
approaches continuous improvement in unique and
innovative ways, through targeted, flexible and scalable
adaptation of the many tools and methods at our disposal.
• The methodologies and systems used by Segla provide a
consistent platform to any learning and have been proven
to achieve results.

Segla International: Key Strengths
• Segla International delivers business efficiency solutions
utilising Six Sigma, Lean and Process Improvement
Methodologies.
• We offer tailored training and consulting services in the
following areas:
–Lean Six Sigma Green and Black Belt Certification;
–Lean & Lean Six Sigma Training Programs;
–Competitive Manufacturing;
–Business process analysis;
–Project management planning and support;
–Complete supply chain optimisation solutions, AND;
–Cultural change programs.

What is Lean Six Sigma?
What it is…
• Lean Six Sigma is a continuous improvement methodology that focuses
upon the elimination of waste and the reduction of variation found within
processes.
Lean
• Pioneered by Toyota, Lean is a methodology which aims to reduce nonvalued
added activities that will lead to the goal of reduced waste and
cycle times.
Six Sigma
• Developed by Motorola and made famous by GE, Six Sigma is a
methodology to identify and reduce variability and thus improve overall
quality and reduce costs.
The combination of these two powerful process improvement
methodologies allows an organisation to build upon its existing
capabilities, to become Safer, Faster and Better able to operate with
Reduced costs, yet in ways which are sustainable.

Lean Six Sigma v’s Other Quality Efforts?
Differences
• Enables closer alignment
with business objectives
• Highly focused upon
delivering business results
• Easily tailored to suit
specific workgroups
• Provides further tools to
key staff – DOE,
hypothesis testing, FMEA,
Kanbans, PokaYoke
Similarities
• Uses some tools already
familiar to people –
fishbone, process flow,
SPC, brainstorming
• Uses a logical problem
solving approach that will
not be new to many
• Aligns with other quality
and reliability efforts –
TQM, Baldrige, Deming

Lean Six Sigma Improvement Cycle
BUSINESS
OBJECTIVES &
MEASURES
VOICE OF
CUSTOMER
5. Control
1. Define
DMAIC
2. Measure
VALUE
STREAM
PROCESS
FLOW
PROCESS
MEASURES
PROCESS KNOWLEDGE
X's
Y's
4. Improve
3. Analyse
UCL
UCL
Avg
Avg
LCL
LCL

Synergy of Lean Six Sigma
Cycle Time Reduction
Variance Reduction
Lean
•5S
•Visual Controls
•IPO
•Cause & Effect
•CNX
Six
Sigma
•Mapping
•Logical
•Physical
•Time
• Process Flow
• KPIs
• SOPs
• Error Proofing
•Testing
•Correlations
•Hypothesis
•DOE
•Faster changeovers
•Batch size reduction
•FMEA
•MSA

Lean Six Sigma: A Set of Tools
1)
1)
Map
Map
the
the
process
process
to
to
determine
determine
where
where
defects
defects
are
are
being
being
created
created
2)
2)
Use
Use
control
control
charts
charts
to
to
understand
understand
and
and
identify
identify
common
common
and
and
special
special
causes
causes
Item
1
2
3
4
5
6
7
8
9
1
0
Measurement System Analysis
Product Inspection Test
Operator 1 Operator 2 Operator 3
Test 1 Test 2 Test 1 Test 2 Test 1 Test 2
3)
3)
Verify
Verify
assessment
assessment
and
and
measurement
measurement
systems
systems
Run A B AB y 1
y
2
y
3
. . . y s
1 - - +
2 - + -
3 + - -
4 + + +
5)
5)
Designed
Designed
experiments
experiments
to
to
make processes robust to
variation
variation
∆ y ˆ
A
∆ = y + A + B
∆ AB
B + A • B
make processes 2 robust 2 to 2
ŝ = ¯s +
δ A
2
A +
δ B
2
B +
δ AB
2
A • B
RISK PRIORITY NUMBER (RPN) =
SEVERITY X 0CCURRENCEX ESCAPED DETECTION
Category 5 4 3 2 1
Severity Severe High Moderate Minor Negligible
Occurrence Very High High Moderate Low
(OCC)
Very Low
4)
4)
Document
Document
failure
failure
modes
modes
for
for
products
products
and
and
processes
processes
to
to
identify
identify
defects'
defects'
root
root
cause
cause
Escaped Very High High Moderate Low Very Low
Detection
(DET)

How does Six Sigma Deliver Results?
Determined by
the customer
Lower
Specification
Limit
3 σ Process
WASTE
-6σ -5σ -4σ -3σ -2σ -1σ 0
Upper
Specification
Limit
+1σ +2σ +3σ
+4σ +5σ +6σ
3 σ Process Centered
• Produce more than
the customer needs i.e.
higher waste
• The Process is
performing outside the
specifications
3 σ Process has
66,807 dpm v’s 3.4
from a 6 σ process
6 σ Process
-6σ -5σ-4σ -3σ-2σ -1σ 0 +1σ+2σ+3σ+4σ+5σ+6σ
6 σ Process Centered
• Produce only what is
required by the
customer i.e. minimal
waste
• The Process is
performing within
specification

Combining Lean & Six Sigma Maximises the Potential Benefits
Overall Yield as a Function of Sigma Level & Process Steps
Sigma Level
No. of Parts or
Process Steps +/- 3 +/- 4 +/- 5 +/- 6
1 93.32% 99.379% 99.9767% 99.99966%
5 70.8% 96.9% 99.884% 99.998%
10 50.1% 94.0% 99.767% 99.997%
50 3.2% 73.2% 98.84% 99.983%
10 0 0.1% 53.6% 97.70% 99.966%
500 0.0% 4.4% 89.0% 99.8%
1,000 0.2% 79.2% 99.7%
5,000 0.0% 31.2% 98.3%
10,000 9.7% 96.7%
50,000 0.0% 84.4%
100,000 71.2%
500,000 18.3%
1,000,000 Six Sigma Only – Improves Quality 3.4%
Lean Only – Removes Steps

How is Our Approach Different?
• Our philosophy focuses upon obtaining the maximum benefits
(i.e. knowledge, ROI etc.) without getting bogged down in
complexity.
• We utilise a knowledge-based approach to pull the use of the
tools, not push them.
• We take a hands-on approach to training, using interactive
exercises and software.
• We provide support and follow up mentoring initiatives using
our proprietary Black Knight TM approach which we believe
ensures that you will see sustainable bottom line financial
benefits.

Lean Six Sigma: The Benefits
• Expanded knowledge of products and processes through
characterisation and optimisation.
• Reduced defects and improved cycle times through improved
operating processes.
• Improved customer satisfaction due to improved quality &
service.
• The development of common tools and process techniques
which can be applied by everyone.
• Improves communication, teamwork and ownership through
the sharing of ideas which when evolved result in improved
processes.
• Processes which are Faster, Safer, Better and able to operate
at Reduced Costs.

Lean Six Sigma: Common Concerns
It’s Just another program!
• Lean Six Sigma is not just another initiative, it is a way of
integrating and improving current practices to achieve sustainable
results.
How soon will we see results?
• Results can be achieved quickly if that is a requirement of the
business however experience has proven that an approach based
upon subtle integration over time, gives the most sustainable
results.
Is the training expensive?
• On-site training is a way to minimise training costs and allows us to
tailor our training to suit your specific requirements.

Lean Six Sigma: Next Steps
• Arrange with us to meet you and/or your team to discuss
your company’s specific needs.
• Develop an Implementation Plan, (Covert v’s Overt approach)
and link to current improvement initiatives.
• Choose potential Black Belt & Green Belt candidates.
• Conduct class room training.
• Identify and commence improvement projects.
• Implement project monitoring and mentoring process, (Black
Knight TM ).
• Develop procedures to identify gaps and other issues that
may arise.

Lean Six Sigma & Segla International
Questions?

Segla Business Efficiency Solutions