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Lean Six Sigma

 Lean Six Sigma is a methodology applied within the projects in the companies aiming at solving the problems using DMAIC cycle: Define – Measure – Analyze – Improve -Control. The methodology combines the principles of Lean (reducing waste, continuous improvement, value stream optimization) with specific Six Sigma statistical tools to determine root causes and making the best decisions.

INVASTA offers:

– COUNSELLING for practical application of this methodology in solving specific problems.

– Training for acquiring Lean / Six Sigma and combining them in problem-solving                        projects using DMAIC cycle.

Training comprises the following :

Module 1 – Six Sigma – Yellow Belt (click here!)

Module 2 – Detailed phases of DMAIC cycle:

Definition: The project objectives, project requirements.

• Project requirements, CTQ forms – Voice of the Customer ( VOC );                    Project Charter draft;

• Problem and objective definition

• Establish the team

• Identify resources

• SIPOC diagram (Supply- Input – Process -Output – Customer); House of                                     quality

• Mapping the chart of the processes involved in the project (High Level Process Map)

• Tree structure of what to do: WBS (Work Breakdown Structure)

• Project stages, activity plan and reporting times (milestones)

• Analysis of those involved directly or indirectly by the project (Stakeholder                                     Analysis)

Measurement: Measurement of the actual parameters of the process (what is process performance?), Which are the proper targets we are planning to achieve through the project ?

• Making detailed chart of the processes

• Writing requirements – VOC – Voice of the Customer

• Establish measurement parameters, of how to collect data on faults (Data                         collection Plan), measurement units; benchmarking

• Analysis of current measurement system – Gauge Repeatability and Reproducibility (Gauge R & R); validation of the system to be used in the project

• Measurement of the process for identifying the relationships between inputs and                  outputs: y = f(x)

• Calculation of current Six Sigma level.

Analysis: determining the causes of faults in the processes involved in the project

• Identify and eliminate wastage in the processes and among the processes by applying Lean tools: 7Wastes and Values ​​Stream Analysis.

• Measurement of the parameters of products (services) and processes to find out the source of variations in the process. Use of appropriate tools to highlight: histograms, Pareto chart, Run Chart coins, Scatter Plot, etc.

• Finding the causes using Mind Mapping, Ishikawa diagram, five whys , Ishikawa diagram, etc. in correlation with statistical analysis, hypothese testing (Continuous & discrete ), etc.

• Establishing determinant factors x (Vital Few) of process relationship Y=f(x)

• Define performance goals that we set in the project

Improvement: generation and testing of new solutions, establishing the solutions                                                   to be implemented.

• Generating and testing possible solutions – brainstorming, experimental solutions in controlled conditions (Design of experiments – DOE), solutions to                            avoid error – Poka Yoke, etc., Setting limits and tolerances of new                                     processes.

• Selecting the best solutions using FMEA, House of Quality, etc.

• Establish the plan to achieve Pilot Studies) – resources, risk management, establishing contingency plan, WBS, budget, control plan;

• Control, feedback and correction for each phase of the pilot program, setting the                               final solution to implement;

Control:  Implementation and documentation of proposed solutions; control of the parameters of implemented solutions, continuous generation of improvement solutions.

• Implementation of the proposed solutions in current practice;

• Preparation of documents, standards and procedures.

• Establish control plan to monitor the persistence in using and integrating new solutions.

• Development and implementation of statistical control plan; monitoring process                        capability where the new solutions have been implemented

• Transfer by the members of the project team to the future user, of the data on implemented solution.

• Documentation by means of indicators of growth of benefits in the entire chain of value stream – Value Stream (profit, costs, quality parameters, etc.

• Complete project documentation, feedback of project team and declaring the project “closed”.

This post is also available in: Romanian