ZERO DEFECTS ZERO DEFECTS THROUGH LEAN-SIGMATHROUGH LEAN-SIGMA

The necessary skill-set to achieve The necessary skill-set to achieve ZERO DEFECTS in fast trackZERO DEFECTS in fast track

withwith

Advanced Manufacturing Consultancy Sdn. Bhd.

ContentsContents

• Why Zero Defects• Brief Background of Lean-Sigma • The AMC Lean-Sigma program

Why Zero DefectsWhy Zero Defects Philip Crosby popularized the concept of Zero Defects Philip Crosby popularized the concept of Zero Defects and he made it clear that there is something called “COST and he made it clear that there is something called “COST OF POOR QUALITY”OF POOR QUALITY”

Defects Defects COST MONEY!COST MONEY!

Today’s business scenario makes it imperative that you Today’s business scenario makes it imperative that you provide Excellent Quality to customers or lose their provide Excellent Quality to customers or lose their businessbusiness

Philip Crosby1926-2001

Most companies implement ‘Zero Defects’ initiatives but Most companies implement ‘Zero Defects’ initiatives but struggle with results due to:struggle with results due to:

Lack of skills and experience in employees to create a Zero Defect environment Lack of motivation and drive to do it

RESULTS ARE SLOW!RESULTS ARE SLOW!

CAN YOU WAIT CAN YOU WAIT YEARS TO ACHIEVE YEARS TO ACHIEVE

ZERO DEFECTS?ZERO DEFECTS?

FAST TRACK APPROACH TO ACHIEVE YOUR TARGETFAST TRACK APPROACH TO ACHIEVE YOUR TARGETAllow us to develop Allow us to develop the skills and the skills and motivation in your motivation in your employees using employees using LEAN-SIGMALEAN-SIGMA methodologies to methodologies to achieve achieve ZERO DEFECTSZERO DEFECTS. . Let them achieve Let them achieve “bulls eye” results “bulls eye” results always with these always with these proven methodologiesproven methodologies

Brief Background Brief Background • Many world class companies have achieved great savings and improvement

through two of the most effective methodologies of this time-Lean and Six Sigma

• However, despite spending lots of money and resources these initiatives have left them with certain drawbacks:

– Six Sigma does not address process speed and lacks improvement in Lead Times– Six Sigma practitioners focus only on improving variations on specific

areas/processes with little impact to overall business– Companies implementing Lean aren’t effective in deploying it across the corporation

at a rapid speed– Lean Tools lack a robust analytical process of problem solving to make change last

• In short:– LEAN CANNOT BRING PROCESS UNDER STATISTICAL CONTROL– SIX SIGMA CANNOT IMPROVE LEAD TIME A GREAT DEAL OR REDUCE

CAPITAL INVESTMENT

Brief Background Brief Background • The solution to this drawback is an approach where Lean & Six Sigma are

merged as a more powerful improvement methodology called LEAN-SIGMA

• The LEAN-SIGMA methods prove to wipeout the weaknesses the tools applied in isolation

• The LEAN-SIGMA methods are already applied widely and successfully by big companies such as:

– GE– Honeywell– NCR– ITT Industries– Rockwell– Raytheon– Caterpillar and many others

AMC has developed the AMC has developed the “Zero Defects Through Lean-“Zero Defects Through Lean-Sigma” Sigma” program by tapping program by tapping on the most powerful tools of on the most powerful tools of Six Sigma & Lean with a Six Sigma & Lean with a

special focus on special focus on Quality Quality ImprovementImprovement

The program is developed with SPEED and RESULTS in mind The program is developed with SPEED and RESULTS in mind and with a clarity and simplicity where the tools can be taught and with a clarity and simplicity where the tools can be taught to even persons without any technical or engineering to even persons without any technical or engineering background. The effectiveness of the tools are guaranteed background. The effectiveness of the tools are guaranteed

BREAKTHROUGH APPROACH WITH LEAN-SIGMA TOOLSBREAKTHROUGH APPROACH WITH LEAN-SIGMA TOOLS

THE PROGRAM DETAILS

ZERO DEFECTS ZERO DEFECTS THROUGH LEAN-SIGMATHROUGH LEAN-SIGMA

Objective of the ProgramObjective of the ProgramThe program is designed to provide hands-on knowledge and The program is designed to provide hands-on knowledge and guidance to participants to use the Six Sigma DMAIC (Define, Measure, guidance to participants to use the Six Sigma DMAIC (Define, Measure, Analyze, Improve & Control) problem solving process to improve Quality Analyze, Improve & Control) problem solving process to improve Quality and eliminate/reduce defectsand eliminate/reduce defects

The program uses Proven Six Sigma statistical tools and selected The program uses Proven Six Sigma statistical tools and selected Lean Tools tailor made to improve process robustness and Quality Lean Tools tailor made to improve process robustness and Quality within a very short period of timewithin a very short period of time

The program is delivered in a pragmatic and easy manner so that The program is delivered in a pragmatic and easy manner so that even non-technical participants can grasp and use the methodology even non-technical participants can grasp and use the methodology immediatelyimmediately

It is targeted to equip those working on Zero Defect projects in an It is targeted to equip those working on Zero Defect projects in an organization with the right Lean-Sigma competencyorganization with the right Lean-Sigma competency

The Program OutlineThe Program OutlineWave 1 (2 DAYS) Background of Quality Excellence and its importance in today’s business scenario Overview of Achieving Zero Defects Through Lean-Sigma: Class Room Simulation Value Stream Mapping & Red Flagging for Quality improvement Measuring Cost of Poor Quality Project Management & Motivation for Zero Defects

The Program OutlineThe Program OutlineWave 2 (3 DAYS) Solving Problems using the DMAIC process Define Phase Tools: Affinity Diagrams, Interrelation Diagram, QFD & SIPOC, 5-Why Measure Phase Tools: Pareto, Gage R & R, Histogram & Process Capability Analyze Phase Tools: C&E, RCA, Scatter charts, multivari charts

The Program OutlineThe Program OutlineWave 3 (4 DAYS) Improve Phase Tools: DOE, Tree Diagram, FMEA, Improve Phase Lean Tools: Robust Setups, TPM Equipment Improvement, Visual Systems & Standardized Work for Quality, 2S for Quality

Wave 4 (3 DAYS) Control Phase Tools: Process Control, Pokayoke, Pareto, Control Chart Case Study

The Program Delivery MethodThe Program Delivery Method The program is delivered in a Learn-Do-Mentor approach which is unique to AMC

Each participant will be required to one practical Quality Improvement or Defect Elimination project using the tools taught through the course of the training

The Wave training are delivered with a 2 – 3 weeks interval to allow participants time and opportunity to use the tools taught on their practical project

AMC consultants will provide 1 day of project mentoring session between each Wave where each participant will spend 1 hour with the consultant

Summary of ProgramSummary of Program

PROGRAM ACTIVITY # DAYSWave 1 2Wave 2 3Projects Mentoring 1Wave 3 4Projects Mentoring 1Wave 4 3Projects mentoring 1Total 15

WHAT NEXT?WHAT NEXT?Allow us to come in and

give a full presentation on this program which

can bring quantum benefits to your company

within a short period of time

YOU CAN SAVE MONEY YOU CAN SAVE MONEY THROUGH QUALITY THROUGH QUALITY

IMPROVEMENTIMPROVEMENT

CONTACT US: Lawrence +6016-566 2810 Fax:+605-526 1090

Email: enquiries@amc-sb.com or lawrence@amc-sb.com