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Section III: Lean and DFSS

Section III: Lean and DFSS. Why do we need Six Sigma?. Total Product or Service Price to Customers. Budget Constraints and Competition Drive a Lowered Price. Profit. Profit. Total Cost to Produce or Provide. Waste (COPQ). Profit. Profit. Price $. COPQ. Theoretical

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Section III: Lean and DFSS

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  1. Section III: Lean and DFSS

  2. Why do we need Six Sigma? Total Product or Service Price to Customers Budget Constraints and Competition Drive a Lowered Price Profit Profit Total Cost to Produce or Provide Waste (COPQ) Profit Profit Price $ COPQ Theoretical Costs i.e.., Cost of Doing the Right Things Right the First Time Waste (COPQ) Theoretical COSTS Theoretical COSTS 0 a. b. c. d. e. “The price of gaining knowledge is nothing compared to the cost of ignorance.” Anonymous III-3

  3. What is a Value Stream? • To map the value stream we need to identify all of the company’s activities, both value added and non-value added from the supply of a product to its ultimate customer. III-5

  4. The 5S Numbers Game: Round 1 • This sheet represents our current work place. • Our job during a 20 second shift, is to strike out the numbers 1 to 49 in correct sequence. Example: 1 23 • The team score will be represented by the lowest individual score achieved. • Give the sheets out face down and have someone keep time. • Ask each person to call out their individual scores and mark them on a flipchart. Circle the lowest and therefore team score. • Ask if they are happy with the score. III-20

  5. 30 48 87 45 72 33 27 3 69 51 21 24 9 18 57 75 78 54 6 36 63 60 12 15 42 81 39 84 66 90 2 53 62 68 86 77 80 74 29 65 5 23 41 20 35 56 89 44 32 8 83 50 47 26 11 17 38 71 59 14 31 61 64 34 49 40 7 28 54 16 52 58 10 76 22 88 73 1 85 4 43 82 25 13 79 37 19 67 46 70

  6. Round 2 • For our first action, we are going to implement 5S in this area. • The first step of this is “Sort” and so we have removed from the area all the numbers from 50 to 90 which are not needed. • Same rules apply. Strike out numbers 1 to 49 in sequence during a 20 second shift. III-20

  7. 30 48 45 33 27 3 21 24 9 18 6 36 12 15 42 39 2 29 5 23 41 20 35 44 32 8 47 26 11 17 38 14 31 34 49 40 7 28 16 10 22 1 4 43 25 13 37 19 46

  8. Round 3 • Having achieved some improvement, we now need to move onto the next step “Straighten.” • We have installed some racking, and we have organized the items so that with Number 1 in the bottom left hand corner, the numbers are located from left to right and bottom to top - examples 1 in the bottom left, 2 in the middle, and 3 in the top left. • Same rules apply 20 second shift, lowest individual score equals team score etc… III-20

  9. 30 48 45 33 27 3 21 24 9 18 6 36 12 15 42 39 2 29 5 23 41 20 35 44 32 8 47 26 11 17 38 14 31 34 49 40 7 28 16 10 22 1 4 43 25 13 37 19 46

  10. Round 4 • Having now made a significant step forward, and having done “Sweep” inclusive for this exercise, we must now “Standardize.” • Since we are dealing with numbers 1 to 49 in sequence, it seems logical to re-organize them in a standard way that makes the completion of the work task as easy as possible. • This should ensure that everyone is able to complete the task (and therefore produce a team score of 49.) III-20

  11. Numbers from 1 to 49 10 2 4 7 8 6 3 5 9 1 16 20 15 17 18 11 19 13 14 12 27 30 21 23 24 25 28 22 26 29 32 31 33 36 37 34 40 39 35 38 47 42 41 44 43 45 49 48 46

  12. Round 5 • To show respect for Standards it is necessary to make the “management” of the area visual. • Returning to our original work area, we have for this assignment two numbers missing. We cannot complete the task without these numbers - so first we have to find them. • Start a clock running and every 20 seconds, tell them how many “shifts” they have been down looking for the appropriate numbers. III-20

  13. 30 48 87 45 72 33 27 3 69 51 21 24 9 57 75 78 54 6 36 63 60 12 15 81 39 84 66 90 2 53 62 68 86 77 80 74 29 65 5 23 41 20 35 56 89 44 32 8 83 50 47 26 11 17 38 71 59 14 31 61 64 34 49 40 7 28 54 16 52 58 10 76 22 88 73 1 85 4 43 82 25 13 79 37 19 67 46 70

  14. Now how much easier is it to find the quality problems? 10 2 4 7 8 6 3 5 9 1 16 20 15 17 11 19 13 14 12 27 30 21 23 24 25 28 22 26 29 32 31 33 36 37 34 40 39 35 38 47 41 44 43 45 49 48 46 Numbers from 1 to 49

  15. III-47

  16. Ejection seat A friend, who was sitting in this mini-van seat, wanted to slide the seat back. He reached down under the front of the seat, feeling for the seat adjustment control. Upon feeling a lever (see arrow), he grabbed it and pulled it. Which of the following do you think happened? • Pulling the lever allowed the seat to slide smoothly back. • Pulling the lever detached the seat from the floor, causing the seat to fall over. III-47

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