Course Description
Lean Six Sigma is a business philosophy leading to the elimination of waste and the reduction of variation. With Lean Six Sigma, costs are being reduced, productivity is raised and customer satisfaction is enhanced. The basic tenants of Lean Six Sigma are: Focusing on customers and their needs; ensuring internal alignment and communication; developing necessary skill sets to improve effectiveness and efficiency; continually assessing all process elements for waste and variation; involving everyone.
Course Objectives
- Gaining an understanding of what waste is and methods of identifying it so that it can be reduced.
- Understanding the scope and breadth of a Lean Six Sigma initiative.
- Becoming aware of variation and techniques to reduce it.
- Becoming familiar with the DMAIC team project model.
- Being aware of the infrastructure needed to support a Lean Six Sigma effort
Course Details/Schedule
- Historical Perspective on Lean/Six Sigma
- Lean Thinking
- Mass and Lean in Historical Context
- Exercises (Seven Wastes, 5S's, Work Cell Redesign)
- Value Stream Maps and Knowledge-Driven Continuous Improvement (PDCA)
- Infrastructure, Stability, Flow and Pull
- Six Sigma Principles
- Variance and Variance Reduction
- DMIAC Process
- Six Sigma Measurement Tools
- Systems Change Principles
- Stakeholders and Systems
- OD Roles
- Strategy, Structure and Process
- "Top-Down" and "Bottom-Up" Change
- Socio-Technical Dynamics
- "Brownfield"/"Greenfield" Contrast
- Active and Passive Opposition to Lean/Six Sigma
- Inadequate or Missing "Social Infrastructure" - Forums, Capabilities, Relationships
- Team/Work Group Structure and Roles - Socio-Tech vs Lean Teams
- Front-Line Leadership Capability and Motivation
- Knowledge-Driven Work
- Support Function Alignment
- Supply Chain Alignment
- Union-Management Partnership
- Standardized Work
- Statistical Process Control and "Control Points"
- Andon Response Systems
- PDCA and Control Point Improvement Processes
- 5S's and Waste Walks
- Preventive Maintenance Principles
- Lean Machine Tooling
- Maintenance/Skilled Trades Work Groups
- Assembly Operations - Takt Time
- Machining Operations - Cycle Time
- Continuous Flow Operations
- Engineering Design Operations Service Operations - Cycle Time
- Sustainability and Lean/Six Sigma
- Kanban/Supply Chain Sequencing
- Presentation of Parts and Parts Marketplace
- Hejunka/Product Leveling
- Kaizen-Teian Improvement Systems
- Hoshin Planning/Policy Deployment
- Enterprise Resource Planning Tools
- Design for Manufacture
- Performance Metric Feedback
- Forecast "Push," Customer "Pull," and Hybrid Models
- The Three-Day Car
- Low Volume and High Complexity in Defense Aerospace
- Fujitsu "Sense and Respond" Customer Support System
- Within-Function and Cross-Functional Challenges in the Transitions from "Pre-Stability" to Stability to Flow to Pull
- Lean Enterprise Alignment
- Enterprise Structure and Alignment
- Value Identification, Value Proposition and Value Delivery in the Enterprise Context
