LEAN system & Six Sigma

1. LEAN system & Six Sigma Lecture 6.

2. Value • That customer is willing to pay • That changes products color, function, shape, other attributes so that the product is getting closer to the customers requirements • That we do right at first time

3. Wastes • Those processes which directly do not create value for customers (muda, mura, muri) : • that are not necessary, and must be eliminated • That are necessary,because these are supporting value-add processes, cannot be eliminated (like transporting) • Muda –7 wastes of lean • Mura– not leveled workflow • Muri– overloading of workers and assets

4. There are 7 wastes in LEAN (TIMWOOD): • Inventory • Overproduction • Waiting • Unnecessary transportation • Processing waste • Inefficient work methods • Defects

5. Lean thinking Operation Traditional improvement Lean improvement Non value-add process Value-add process

6. Supporting goals • A balanced system, smooth, rapid flow of materials and/or work • Supporting goals: • Eliminate disruption • Make the system flexible • eliminate waste, especially exess inventory

7. Tools of LEAN relating to quality

8. Quality improvement - Jidoka • Autonomation – automatic detection of defects during production. • It consist two activities: • One for detecting defects when they occure • Another for stopping production to correct the cuase of defects.

9. Fail- Safe methods – Poka Yoke • Methods: • The contact method identifies product defects by testing the product's shape, size, color, or other physical attributes. • The fixed-value (or constant number) method alerts the operator if a certain number of movements are not made. • The motion-step (or sequence) method determines whether the prescribed steps of the process have been followed.

10. Kaizen • Improvement in small steps • Refers to the philosophy of continuous improvement • Video • 3 gen: • Gem-ba – actual place • Gen-butsu – actual part • Gen-jitsu – get the facts

11. Kanban Production Control System • Kanban is the Japanese word meaning “signal” or “visible record” • Sign to produce • Sign to transport • Paperless production control system

12. Preventive maintenance and housekeeping • 5S • Sort –decide which item is needed • Straighten – needed items can be assessed quickly • Sweep – clean workplace • Standardize – use standard intructions • Self discipline – make sure that employees understand the need for uncluttered workplace

13. Six Sigma

14. 1 σ – 691 462 ppm 2 σ – 308 538 ppm 3 σ – 66 807 ppm 4 σ – 6 210 ppm 5 σ – 233 ppm 6 σ – 3,4 ppm Video 3 sigma process 1 sigma process USL LSL mean 3σ 3σ 5% is out of limits!

15. Define Measure Analyze Improve Control Plan Do Check Act DMAIC PDCA

16. 1. Define • Determine case studies • RUMBA • Project evaluation • Pareto analysis • Problem defintion

17. STARS ? LOW-HANGING FRIUTS DOGS Project Risk and Return matrix 100 90 80 70 60 50 40 30 20 10 0 Rwturn factor Risk factor 0 10 20 30 40 50 60 70 80 90 100

18. 2. Measure • Select process outcome • XY matrics - relationship • FMEA – risk of parts • SPC – process performance • Verifying measurements • R&D evaluation

19. 3. Analysis • Define objectives • Define Xs • Analyse source of variation 4. Improve • Off-lineexperiments – Taguchiexperiment 5. Control

20. Thank you for your attention!