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Six Sigma at Savannah River Site: A Black Belt’s Perspective Jessica Urbanik Coughlin Washington Savannah River Co., Inc. North American Young Generation in Nuclear Six Sigma: Sizing Up the Industry May 17, 2006 The Fairmont, San Francisco, CA

Jessica Urbanik Coughlin

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Page 1: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site:A Black Belt’s Perspective

Jessica Urbanik CoughlinWashington Savannah River Co., Inc.

North American Young Generation in NuclearSix Sigma: Sizing Up the Industry

May 17, 2006The Fairmont, San Francisco, CA

Page 2: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

Topics

• Snapshot: Savannah River Site at 50+ Years

• Six Sigma Deployment at SRS: Saving Your $$$

• Living La Vida Sigma: Career Development through Black

Belt Assignment

Page 3: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

SRS at a Glance

Future: Stabilization, storage, and preparation for final disposition of nuclear materials; Legacy clean-up; Alternative fuel research; MOX

Past: Nuclear material production critical to developing and maintaining a strong nuclear deterrent

Present: DOE oversight of WSRC-led team of contractors; 9,100 employees; 1 National Lab

Page 4: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

SRS: Doing More with Less

At SRS, there is no better time to use Six Sigma:• Increasing Customer Expectations• Less Money, Less People• Increased Scope

Examples of Six Sigma Success:• Reduce Sampling Costs - $16M• Shut-down Cold War-era facilities ahead of schedule, $8M• Increase rate of shipping waste off-site, $2M + increased customer (DOE & public) satisfaction

Page 5: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

Deployment Strategy: Driven from Top

WSRC PresidentExecutive Sponsor

Business Unit Director

Business Unit Director

Business Unit Director

Business Unit Director

Dept/Proj Mgrs

PIP Champions

Program Coord.

Dept/Proj Mgrs

PIP Champions

Dept/Proj Mgrs

PIP Champions

Dept/Proj Mgrs

PIP Champions

Legend:

•Deployment Champions = Core Team

•Project & Dept Mgrs

•PIP Champions

•Program Support Staff

MasterMasterBlack BeltBlack Belt

Sr. ManagerSr. ManagerWSRC Site Deployment WSRC Site Deployment

ChampionChampion

Prgm Asst.Prgm Asst.

MasterMasterYellow BeltYellow Belt

Black BeltBlack Belt

SIX SIGMA RESPONSIBILITIES

• Provide executive direction and guidance.Provide executive direction and guidance.

• Provide leadership for strategic application of Six Provide leadership for strategic application of Six SigmaSigma

• Core Team ChairpersonCore Team Chairperson• Black Belt selection , compensation, and reintegrationBlack Belt selection , compensation, and reintegration• Manage Six Sigma BudgetManage Six Sigma Budget• Support corporate implementation initiativesSupport corporate implementation initiatives• Site communication of achievementsSite communication of achievements

• Manage all aspects of Six Sigma within B.U. Manage all aspects of Six Sigma within B.U. • Core Team memberCore Team member• Provide strategic recommendations, business plan, Provide strategic recommendations, business plan,

and communicate successes.and communicate successes.

• Lead Six Sigma within each Department / Project.Lead Six Sigma within each Department / Project.• Establish performance expectations and Establish performance expectations and

accountabilities.accountabilities.

• Initiate strategic business cases and PIP objectives Initiate strategic business cases and PIP objectives and support Black Belt and Yellow Belt Projects.and support Black Belt and Yellow Belt Projects.

• Establish performance expectations and Establish performance expectations and accountabilities.accountabilities.

• MBB, MYB, BB, & Program AdministrationMBB, MYB, BB, & Program Administration

Page 6: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

Deployment Timeline: 2000 to Present

$$$$2000

Six SigmaInitiated

Black BeltPIPs

2001 2002 2004

DeploymentChampions

Trained

Yellow BeltProjects

Design forSix Sigma

“We Fix What’s Broken”

“We EvaluateProcesses forImprovement”

“We Design forSix Sigma”

Yellow BeltsTrained

DevelopmentChampions

Trained

2003 2005 2006

“We UseSix Sigma Every Day”

Integrate Six Sigma into Work

Processes

Black Belts

Trained by Bechtel

Page 7: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

Black Belt Deployment 2001-Present

Black Belt Resources

02468

101214

Apr

-01

Oct

-01

Apr

-02

Oct

-02

Apr

-03

Oct

-03

Apr

-04

Oct

-04

Apr

-05

Oct

-05

Apr

-06

Oct

-06

Date

Co

un

t

Master BB &CandidatesBB - Certified

BB -Candidates

BB:5 week training +

7 month certification

Page 8: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

Champion & Yellow Belt Deployment

Six Sigma Engagement of Active SRS Resources

FY06 April 30, 2006

0

100

200

300

Resource Type

Cou

nt

# StatusActive

39 138 251

# WorkingProj

28 88 182

Deployment Champ

PIP Champ Yellow Belt

Employee Development via

Six Sigma:

Champions: 2 day training + 3month

certification

YB: 5 day training + 3 month certification

Page 9: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

Savings To Date ($K)

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

Grand Total Black BeltLed PIPs

Yellow BeltLed PIPs

Savings Breakdown ($K)

ProductivityImprovements ($K)

Hard Savings ($K)

$325M$325M

56% Hard Savings56% Hard Savings44% Productivity44% Productivity

53% BB53% BB47% YB47% YB

Page 10: Jessica Urbanik Coughlin

Potential Growth &Potential Growth & Future Value to WSRC?Future Value to WSRC?

Six Sigma at Savannah River Site

Six Sigma Career Makeover: Before BB

3.5 yrs with WSRCComfortable in Analytical Labs

Some technical challengesNo management mentor

No clear career path (management vs. technical?)

PersonalPersonal COMFORT ZONECOMFORT ZONE

•Chemist (M.S.)•3.5 yrs with WSRC

•Comfortable in Analytical Labs•Some technical challenges•No management mentor

•No clear career path (management vs. technical?)

Page 11: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

To Be a Black Belt: What’s In It For Me?

Enjoy multi-tasking Enjoy analyzing data Want to work for an org that uses objective

evidence, not “Tribal Knowledge”, to make decisions Program rewards success

Received management support and backingSelected as Black Belt Candidate 2004Scheduled to Reintegrate in 2007

YES!YES!

Page 12: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

Black Belt – Employee Development Model

CandidateCandidate•Hi Potential

•Hi Performer•Career Goals Aligned with Assignment

SELECTIONSELECTION

REINTEGRATIONREINTEGRATION

PerformancePerformanceManagementManagement

Black Belt Black Belt Effective-Effective-

nessness

Active BBActive BB•PIP Production•Career Track Development

•Mentor BBC/YB

ReintegratedReintegrated•Aligned

Leadership Expectations

•Clear Goals & Objectives

FunctionalManagement:Engagement

Deployment Champion:Define and

Communicate Expectations

Deployment Champion:

Ensure Leadership Role

FunctionalMgmt:

Acceptance

Both:End-in-Mind

FunctionalMgmt:

Career Track Development

Deployment Champion:Business &

Performance Goals Alignment

Both:Communicate Expectations

Page 13: Jessica Urbanik Coughlin

Potential Growth &Potential Growth & Future Value to WSRC?Future Value to WSRC?

Six Sigma at Savannah River Site

Six Sigma Career Makeover: After BB

5 yrs with WSRCLearning the Entire Business

Variety of challenges each dayYes management mentor

Developing clear career path (Project Management)

PersonalPersonal COMFORT ZONECOMFORT ZONE

•5 yrs with WSRC•Learning the Entire Business

•Enhancing Soft Skills•Solve challenging problems daily

•Sr. Management Mentor •Developing clear career path

(Project Management)

Page 14: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

BB Performance to Date:

Personal Performance Measures:“Banked $900K for FY06; Forecast $1.6M Completed 4 PIPs; 3 More >75% complete

Personal Development:Enjoy Facilitating Teams, not just working with dataLeaving comfort zone to “cold call” for assistanceMentoring BB candidateDesign for Six Sigma subject matter expertHave senior management mentor: align reintegration plan with career objectives

Page 15: Jessica Urbanik Coughlin

Six Sigma at Savannah River Site

Summary

Six Sigma is for SRS:

Helps Us Do More with LessExpectations Set by Senior Management Develops and Helps Retain Top Talent

Six Sigma is for Black Belts:

Enjoy Working with PeopleUse Data to Make Better DecisionsSuperb Development Opportunities Outside of the

Comfort Zone