Lean Process And Six Sigma
Module One: Getting Started Welcome to the Six Sigma workshop. The last couple of decades companies have embraced Six Sigma to generate more profit and greater savings. So what is Six Sigma? Six Sigma is a data-driven approach for eliminating defects and waste in any business process.
Quality means doing it right when no one is looking. Henry Ford
Workshop Objectives
360 degree view
Dimensions of quality
Evaluate a project
Module Two: Understanding Lean Lean and Six Sigma are buzz-words we hear in business all of the time. Before we get started, let’s make sure we all understand just what we mean by “lean” and “Six Sigma”.
Six Sigma is the most important training thing we have ever had. It’s better than going to Harvard Business School. Jack Welch
About Six Sigma Structured
Data driven
Problem solving
Improvement process
About Lean
Continuously improving towards the ideal
History Behind Lean Traced back to Benjamin Franklin Toyota Inspired by Henry Ford Common sense
Toyota Production Systems Define Value of your product Identify Value Stream Study the Flow Make only what the customer orders Strive for Perfection
The Toyota Precepts Challenge Kaizen Genchi genbutsu (Go and see) Respect Teamwork
Module Two: Review Questions 1)Six sigma equates to: a)1.4 DPMO b)2.4 DPMO c)3.4 DPMO d)4.4 DPMO
3)Which letter is used Sigma capability? a)S b)C c)Y d)Z
Module Two: Review Questions 3)Which of the following actions is not so typical for the lean process? a)Eliminating waste b)Eliminating people c)Reducing costs d)Shortening time cycles
4)Which of the following is not an example of lean process? a)Reduced inventory b)Increasing overall productivity c)Decreased defects d)Skipped details in reports
Module Two: Review Questions 5)Which car company’s production system is related with early usage of ‘lean manufacturing’? a)Mercedes-Benz b)Toyota c)General Motors d)BMW
6)Besides “The machine that changed the world”, which book also shaped the ideologies of ‘Lean’? a)“Lean process” b)“Lean manufacturing” c)“Lean thinking” d)“Lean world”
Module Two: Review Questions 7)What was the original name of TPS? a)Just in time production b)Just right production c)Just precise production d)Just appropriate production
8)What is the last step of TPS? a)Defining value of your product b)Striving for perfection c)Making only what the customer orders d)Studying the flow of your product
Module Two: Review Questions 9)What does GENCHI GEBUTSU mean? a)Wait and see b)Come and see c)Go and see d)Look and see
10)Committing to education and development is especially important for: a)Respect b)Kaizen c)Challenge d)Teamwork
Module Two: Review Questions 1)Six sigma equates to: a)1.4 DPMO b)2.4 DPMO c)3.4 DPMO d)4.4 DPMO
3)Which letter is used Sigma capability? a)S b)C c)Y d)Z
Module Two: Review Questions 3)Which of the following actions is not so typical for the lean process? a)Eliminating waste b)Eliminating people c)Reducing costs d)Shortening time cycles
4)Which of the following is not an example of lean process? a)Reduced inventory b)Increasing overall productivity c)Decreased defects d)Skipped details in reports
Module Two: Review Questions 5)Which car company’s production system is related with early usage of ‘lean manufacturing’? a)Mercedes-Benz b)Toyota c)General Motors d)BMW
6)Besides “The machine that changed the world”, which book also shaped the ideologies of ‘Lean’? a)“Lean process” b)“Lean manufacturing” c)“Lean thinking” d)“Lean world”
Module Two: Review Questions 7)What was the original name of TPS? a)Just in time production b)Just right production c)Just precise production d)Just appropriate production
8)What is the last step of TPS? a)Defining value of your product b)Striving for perfection c)Making only what the customer orders d)Studying the flow of your product
Module Two: Review Questions 9)What does GENCHI GEBUTSU mean? a)Wait and see b)Come and see c)Go and see d)Look and see
10)Committing to education and development is especially important for: a)Respect b)Kaizen c)Challenge d)Teamwork
Module Three: Liker’s Toyota Way
Do you value practices, or do you practice values? Anonymous
In this module we will look closer at Toyota’s philosophies that have become a spiritual pinnacle of modern manufacturing. “The Toyota Way” is a book about the 14 principles that drive Toyota’s culture.
Philosophy Decisions based on a long-term philosophy Generate value for the customer, society, and the economy Accept responsibility for its conduct
Process Redesigned to eliminate waste Stop to fix problems Use tested technology
People and Partners
Grow leaders Develop teams Respect partners
Problem Solving Go see for yourself Consider all options Become a learning organization
Module Three: Review Questions 1)How many principles are in Dr. Jeffrey Linker’s book “The Toyota Way”? a)6 b)7 c)10 d)14
3)In Toyota’s vision, what’s the most important thing for a company’s philosophy? a)To be original b)To be verified c)To be long-term d)To be safe
Module Three: Review Questions 3)According to 3rd principle, what kind of system should you use to avoid overproduction? a)Push b)Pull c)Drag d)Scratch
4)According to 7th principle, what kind of control should we use to make all the problems visible? a)Digital b)Classical c)People d)Visual
Module Three: Review Questions 5)According to 4th principle (Heijunka), we should work like: a)Ants b)Bees c)Turtles d)Rabbits
6)Which principles refer to people and partners? a)1, 2, 3 b)5, 6, 7 c)9, 10, 11 d)12, 13, 14
Module Three: Review Questions 7)According to one of the principles, how do you respect the extended network of partners and suppliers? a)By awarding them b)By criticizing them c)By including them in more company’s activities d)By challenging them
8)Which of the following is not necessary for a good leader? a)Understanding the work b)Leaving the philosophy c)‘Teaching’ that philosophy to others d)Upgrading that philosophy
Module Three: Review Questions 9)What are the last principles related to? a)Problem solving b)Profit c)Management d)Personal development
10)What is Kaizen? a)Continuous work b)Continuous problem solving c)Continuous improvement d)Continuous earnings
Module Three: Review Questions 1)How many principles are in Dr. Jeffrey Linker’s book “The Toyota Way”? a)6 b)7 c)10 d)14
3)In Toyota’s vision, what’s the most important thing for a company’s philosophy? a)To be original b)To be verified c)To be long-term d)To be safe
Module Three: Review Questions 3)According to 3rd principle, what kind of system should you use to avoid overproduction? a)Push b)Pull c)Drag d)Scratch
4)According to 7th principle, what kind of control should we use to make all the problems visible? a)Digital b)Classical c)People d)Visual
Module Three: Review Questions 5)According to 4th principle (Heijunka), we should work like: a)Ants b)Bees c)Turtles d)Rabbits
6)Which principles refer to people and partners? a)1, 2, 3 b)5, 6, 7 c)9, 10, 11 d)12, 13, 14
Module Three: Review Questions 7)According to one of the principles, how do you respect the extended network of partners and suppliers? a)By awarding them b)By criticizing them c)By including them in more company’s activities d)By challenging them
8)Which of the following is not necessary for a good leader? a)Understanding the work b)Leaving the philosophy c)‘Teaching’ that philosophy to others d)Upgrading that philosophy
Module Three: Review Questions 9)What are the last principles related to? a)Problem solving b)Profit c)Management d)Personal development
10)What is Kaizen? a)Continuous work b)Continuous problem solving c)Continuous improvement d)Continuous earnings