Lean/Six Sigma
Lean Overview
Value Stream Mapping
Quick Changeover
Visual Controls and 5S
Overall Equipment Effectiveness
Poka-Yoke
Standardized Work
Six Sigma Green Belt
Six Sigma Black Belt
Lean Overview
Days: 1
Prerequisites: None
Course Outline:
Chapter 1
• Identify waste
• Removal of waste
• Visual Work Place - color coding, etc.
• Kanban
• Design of Work Place
• Time and Motion
• Sort, Set In Order, Standardize, Shine, Sustain
Chapter 2
• Teamwork / Employee Empowerment
• Single Minute Exchange of Dies
• Value Stream Mapping
• Theory of Constraints (brief)
• Total Productive/Preventive Maintenance
•
Chapter 2
• Plant / Process Layout
• Kaizen Events
• Just In Time
• Overall Equipment Effectiveness
• Lessons Learned
• Continual Improvement
Value Stream Mapping
Days: 1
Prerequisites: None
Course Outline:
Chapter 1
• What is Value Stream Mapping and why do we do it?
• Steps to VSM
• Draw current situation
• Direct process observations
• Identify 7 Wastes
• Draw future situation
• Identify safety, quality, delivery, cost
• Create improvement plan
Quick Change-Over
Days: 1
Prerequisites: None
Course Outline:
Defining: Quick Change-Over
In this training the participants will be trained on all the topics below and participate in the actual creation of a Value Stream Map, Process Layout (Material Flow), Single Minute Exchange of Dies, etc.
One of the key elements of this training is understanding time and motion. Time and motion is the key to quick change-over. The participants will understand the importance of time and motion in relation to Quick Change-Over.
Value Stream Mapping (controllable / non-controllable)
Total Productive Maintenance -TPM (Predictive / Preventive)
Process Layout / Plant Layout
Kaizen Events
Just In Time Manufacturing - JIT
Single Minute Exchange of Die - SMED
Overall Equipment Effectiveness - OEE
Visual Control / 5S
Days: 2.5
Prerequisites: None
Course Outline:
What is Lean?
Lean is a concept that involves the removal of waste from every step in the production chain - waste of energy, motion, time, and resources.
*7 types of waste
Lean keeps cost down so that companies can remain competitive.
Pre-requisites: (Detailed)
Communication
Teamwork
Employee Empowerment
Management Support
Training
How does Lean Manufacturing work? (Detailed)
Step 1 Define waste
Step 2 Identify the source
Step 3 Plan for the elimination of waste
Step 4 Establish permanent controls to prevent reoccurrence
5S
-Textbook definition
5S - define every step of this process
-Sort (hit lightly on the 7 types of waste - prepare for lean overview)
*Red Tag Hold Area
-Set in order
*organization, labeling, structure, etc
-Standardized
*work instructions, job descriptions, methods, procedures, etc
-Shine
*tools, techniques, visual displace examples
-Sustain
*Management Responsibility, Tools & Methods to sustain
Additional Information: What will happen if you do not sustain? What will happen if you stop after shine? What will happen if you do not build a system that is understood and standardized? What will happen without management support? What will happen without resources and time to implement?
Visual Controls -Textbook definition
Types of Visual Controls
-Pictures
-Colors
-Lights
-Sounds / Noise
-Shapes / Sizes
-Location
When, where, why and how to use visual controls:
When: whenever possible for clarification / understanding (Barriers: Language, Color Blindness, Special Needs, etc.)
-Examples: Color Blindness, Statistics on illiteracy, etc.
Where: universal system, it can be used anywhere (examples: home, play, office, etc.)
Why: Safety, Quality, Cost, Delivery
Makes the operators job easier
Visual Work Place - define
Easier to formulate controls for required customer documentation
How: by using a standardized method for implementation that is used in the office and on the production floor (repetition and consistency)
Who: is responsible for visual controls?
-Everyone is responsible for visual controls
Overall Equipment Effectiveness (OEE)
Days: 1
Prerequisites: None
Brief Course Outline:
Monitoring & Improving Manufacturing Processes
Reduction of Complex Production Problems
OEE Factors
1. Availability
2. Performance
3. Quality
Six Big Losses
1. Breakdown
2. Setup & Adjustments
3. Small Stops
4. Reduced Speed
5. Startup Rejects
6. Production Rejects
OEE = A x P x Q
Application Simulations during the training
Poka-Yoke / Error Proofing / Mistake Proofing
Days: 1
Prerequisites: None
Course Outline:
Overview of Poka-yoke:
Three major inspection techniques
Zero Quality Control (three components)
-Shigeo Shingo
Types of Poka-yoke Devices
Successful Modern Factory
All about Defects
All about Poka-Yoke
Achieving Mistake-proofing, Zero-defect Manufacturing through Poka-Yoke
Types of Errors: (sample)
Processing Errors
Assembly Errors
Mounting Errors
Measurement Errors
Dimensional Errors
Operating Errors
Six Sigma - Green Belt Training
10 day Syllabus
Week 1
Day 1 (9:00 - 3:30) DMAIC Overview
Day 2 (9:00 - 3:30) Define
Paradigm Video / History of Six Sigma
Senior Management's Role
Movie - "The Goal" / Discussion
Day 3 (9:00 - 3:30) Measure
"Supersize Me" movie
Group Exercises
Day 4 (8:00 - 12:00) ½ Day Team Exercise #1
Week 2
Day 5 (9:00 - 3:30) Analyze
Group Exercises
Brain Storming on Potential Company Projects
Day 6 (9:00 - 3:30) Improve
Group Exercises
5-S
Day 7 (9:00 - 3:30) Control
Group Exercises
Day 8 (8:00 - 12:00) ½ Day Team Exercise #2
Week 3
Day 9 (9:00 - 3:00) All Material Review
Day 10 (8:00 - 1:00) Open Book Exam
Black Belt Training Agenda - Lean Six Sigma
Week 1&2 Define, Measure, Analyze
1 Day Lean/Six Sigma Overview
Courier Simulation
Define Phase Why Lean/Six Sigma?
DMAIC problem-solving model: Move It!
Project Criteria/Selection
Value Stream Mapping
Value Added/Non Value Added
SIPOC
Voice of the Customer (VOC)
5S
4 Days Measure Phase Data collection planning
Operational definitions
Sampling
Gage R&R-Determine Measurement
System Consistency
Patterns in Data
Types of Variation-Special, Common
Process capability and Sigma
calculations
5 Days Analyze Phase Project Presentations
VA/NVA Analysis
Cycle Time
Takt Analysis
Cause & Effect Analysis
Normal Theory
Transform Data
Hypothesis testing
- T-tests
- Paired t-tests
- Chi-Square
- ANOVA
- EWMA
Regression
- Linear
Project Mentoring
Black Belt Training Agenda - Lean Six Sigma (cont'd)
Time
Topic Content
Week 3&4 Analyze, Improve, Control
3.5 Days Analyze Phase
Design of Experiments
Full Factorial experiments
Analyzing factorial experiments
Confounding
Project Mentoring as time allows
1.5 Days Improve Phase
Generate/Select Solutions
Design of Experiments
Implement/Check Results Idea generation techniques
Selection strategies
Plackett Burman fractional factorial
designs
Just-In-Time System
Pull Systems
Load Leveling and Sequencing
Total Productive Maintenance
Supplier Relations
Autonomation, Mistake Proofing
Mapping Process Flow
Kaizen
Potential Problem Analysis/FMEA
Piloting
Evaluating Results
Planning for Change
4 Days Control Quality control
Cross-training
Documentation
Standardized Work
Mistake proofing
Monitoring
Advanced control charts (x bar and r, individual, p, np, c, u charts)
Visual Management (Andon)
1 day Review & Graduation Project Reviews and Mentoring