Paul White - Oakland Consulting

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  • OAKLAND CONSULTING

    DRIVER A European Lean Six Sigma Process

    Improvement Methodology

    Paul White Oakland Consulting

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    CONSULTING

    Agenda

    Oakland Consulting

    Process Improvement Methodologies

    Lean Principles

    Six Sigma Overview

    DRIVER:

    > Process Focus

    > Deployment Strategy

    European Aeronautical Defence Sector (EADS)

    EADS DRIVER Case Study

    Questions & Answers

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    Some of our Private Sector Clients

    http://www.paceelectronics.com/Default.aspxhttps://www.nationalgridus.com/http://www.nationalexpress.com/index.html
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    Some of our Public Sector Clients

    http://www.nhs.uk/http://www.dh.gov.uk/en/index.htmhttp://images.google.com/imgres?imgurl=http://www.nonnativespecies.org/pics/hmrc_logo.jpg&imgrefurl=http://www.nonnativespecies.org/&h=63&w=162&sz=34&hl=en&start=3&um=1&tbnid=O0fB353Qy0itAM:&tbnh=38&tbnw=98&prev=/images?q=HMRC+logo&um=1&hl=en&rls=GGLD,GGLD:2005-12,GGLD:en&sa=N
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    Workshop Discussion

    What methods can we use to protect the customer?

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    100% Inspection Does it work?

    Workshop Discussion

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    Will 100% inspection protect the customer?

    Scenario

    Marketing Department are very proud of the

    publications they produce.

    The customers of Oakland expect the highest quality

    publications.

    Therefore, the manager of the publications department has

    decided to employ you as an inspector at the end of the printing

    process to ensure that the text produced is accurate.

    You have 30 seconds to inspect the following set of text and

    count how many times the letter appears, (upper & lower

    case) including the title.

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    Finished files are the results of many

    years of sceintific studies combined

    with the experience of many years of

    effort

    F-Test

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    How many did you see?

    Have another look!

    F-Test

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    Finished files are the results of many

    years of sceintific studies combined

    with the experience of many years of

    effort

    F-Test

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    Did anyone change their mind?

    F-Test

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    Finished files are the results of many

    years of sceintific studies combined

    with the experience of many years of

    effort

    F-Test

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    Did you spot anything else?

    F-Test

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    Finished files are the results of many

    years of sceintific studies combined

    with the experience of many years of

    effort

    F-Test

    F-Test

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    100% Inspection Does it work?

    Workshop Discussion

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    Process Improvement Methodology Objective

    Waste Elimination / Defect Reduction

    Efficiency / Yield Improvement

    Improved Customer Satisfaction

    Higher Shareholder Value

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    Process Improvement Methodologies

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    Plan, Do, Check, Act

    Check

    What

    happened?

    Measurement

    Assessment

    Analysis

    Do

    What

    action?

    Prepare for implementation

    Training

    Communication

    Implement improvement

    Change management

    Project management

    Plan

    What

    focus?

    Project goals/measures

    Set up team

    Map process

    Measure process

    Identify key problems

    Find root causes

    Identify solution

    Plan for implementation

    Act

    What

    now?

    Review

    Project revision

    Standardisation

    Share learnings

    Further improvement

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    1. Identify the team Build cross-functional team

    2. Define the problem

    Where, when, etc. Is/Is not analysis Process map Measure and set objective

    3. Contain the symptom Short-term solution Rescue affected customers

    4. Identify root causes Use FMEA, Five Whys Identify and check root cause

    5. Choose corrective action Focus on fixing root causes Set targets and owners for implementation

    6. Implement corrective action Implement to plan Collect data to prove success

    7. Make change permanent Documentation Revise targets, FMEAs, etc.

    8. Recognise the team Recognise individuals and the team Celebrate success

    Global 8D

    0. Emergency Response Action Protect the customer

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    DMAIC

    Define

    Measure

    Analyse

    Improve

    Control

    Identify champion and owner Initial assessment of situation Define scope and goals of project

    Map process Validate measurement system Calculate process capability

    Analyse for sources of variation Identify potential root causes Verify actual root cause

    Develop solution Create new process map Cost / benefit analysis

    Standardise Sustain the gain Develop control strategy

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    DRIVER A European Lean Six Sigma Improvement Methodology

    D Define Define the scope and goals of the improvement project in terms of

    customer and/or business requirements and the process that delivers

    these requirements.

    R Review -

    -

    I Investigar Analyse the gap between the current and desired performance,

    prioritise problems and identify root causes of problems.

    V Verbessern Generate the improvement solutions to fix the problems and prevent

    them from reoccurring so that the required financial and other

    performance goals are met

    E Execute This phase involves implementing the improved process in a way

    systems such as EN 9100 and standards of performance will be

    established using techniques such as Statistical Process Control

    R Renforcer process re-assessment for continuous improvement

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    Methodology Comparison

    1. Identify team

    2. Define problem

    3. Contain

    symptom

    4. Identify

    root causes

    5. Choose

    corrective action

    6. Implement

    corrective action

    7. Make change

    permanent

    8. Recognise the

    team

    Define

    Measure

    Analyse

    Improve

    Control

    Do

    Act

    Check

    Plan

    PDCA DMAIC 8D

    Define

    Review

    Investigar

    Verbessern

    Execute

    DRIVER

    Renforcer

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    DRIVER A holistic approach

    VariationWaste

    TIME

    COST

    QUALITY

    Process

    Improvement

    Lean Six Sigma

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    Lean Principles

    Cost

    QualityTime

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    Lean Principles

    Lean principles are based on the Toyota Production System (TPS)

    TPS was developed after benchmarking the Ford Motor Company

    The key characteristics of TPS / Lean are:

    > Only producing what is required, when it is required

    > Close links throughout the supply chain just in time

    > Producing right first time

    > A lean mindset & company culture

    > The elimination of non-value added activity (waste)

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    -Add

    Total Throughput Time = Value-

    add time

    Non-Value Add +

    Other time +

    Lean

    Eliminate Waste to Improve the Value Stream

    Usual Focus

    Work longer-harder-faster,

    add people, complexity or

    equipment

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    Over-production

    Motion

    Inventory 1

    6

    7

    5 4

    3

    2

    WASTE

    Waiting

    Defects (Scrap/Rework)

    Over-processing

    Transportation

    The 7 wastes

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    LEAN Concepts

    Standardised Work

    Waste Elimination

    Parallel Processing

    Cell Layout

    Batch Reduction

    Quick Changeover

    Line Balancing

    Other Concepts

    Visual Management

    5 S

    Error Proofing

    A Lean Example

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    Workshop Discussion

    Are Lean principles only applicable to manufacturing processes?

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    Six Sigma Overview

    Cost

    QualityTime

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    What is Six Sigma?

    Six Sigma is focused on improving the quality of our products and

    services

    How do we define the term

    The generic definition of quality is or exceeding the customer

    The customer of a process can be internal or external

    Therefore, Six Sigma improves quality, thus, improving customer

    satisfaction

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    Six Sigma Satisfying the Customer

    Defects Defects Acceptable

    LSL USL

    Customer Requirement

    Process Performance

    Sigma is a capability metric that compares process

    performance against customer requirements

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    Is 99% Quality Good Enough?

    6 Sigma

    99.99966% Good

    1 short or long landing every 5 years

    3.8 Sigma

    99% Good

    2 short or long landings at an airport per

    day (200 daily flights)

    Unsafe drinking water for almost 15

    minutes each day

    Unsafe drinking water one minute every

    seven months

    5,000 incorrect surgical operations per week

    (500,000 operations per week)

    1.7 incorrect operations per week

    10,700 defects per million opportunities 3.4 defects per million opportunities

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    Quantifying Process Capability

    VARIABLE DATA

    Cp

    Pp Ppk

    Cpk

    ATTRIBUTE DATA DPMODPUPPM

    } Sigma is a universal measure of process performance

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    Variable process capability is the ability of a process output

    specification limits which are defined by the customer requirements.

    Variable Process Capability Analysis

    4 3 5 6 7 4 3 5 6 7

    Can this distribution from a process output fit between the specification limits of 5 1?

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    LSL USL

    Tolerance Process spread

    LSL USL

    Mean

    Capability is an assessment of: process spread as a ratio of the process

    tolerance. Cp / Pp

    Cpk / Ppk is the location of the process mean with respect to both

    process specification limits.

    Variable Process Capability Analysis

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    Cp =

    Cp =

    Cp =

    Cp =

    Cp =

    LSL USL

    1

    3

    2

    0.5

    1

    Workshop Exercise Cp

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    Cpkl = 1

    LSL USL X

    Cpkl = 5

    X

    Cpkl = 1 X

    Cpkl = 0.5

    X

    Cpkl = 3

    X

    Cpku = 1

    Cpku= 1

    Cpku = 3

    Cpku= 0.5

    Cpku = -1

    Workshop Exercise Cpk