Lean Six Sigma Approach How Start Process Improvement

Improve: Correct and prevent defects using process optimization. Control: Continuously check whether the implemented improvements are having the desired effects and check for new optimization opportunities. Without a doubt, practicing Lean Six Sigma process improvement with employees in a complementary way can give you satisfactory results.

One of the core techniques behind any process improvement, particularly in Six Sigma, is DMAIC. This handy approach, pronounced duh-may-ik, is the key to employing Six Sigma and beginning your journey to being a process hero.

Some more basics of Lean Process Improvement: 1 Define – This is where you determine your goal. 2 Measure – This is where you are specific about the data you will look at 3 Analyze – Here you look at root causes to solve problems and meet your goal. 4 Generate – Look here at solutions. 5 Implement – Take action with your solution. More …

Lean Six Sigma Approach How Start Process Improvement diagram

FIFO First in first out explained

How First In, First Out (FIFO) Works The FIFO method is used for cost flow assumption purposes. In manufacturing, as items progress to later development stages and as finished inventory items are sold, the associated costs with that product must be recognized as an expense.

First-In, First-Out (FIFO) is one of the methods commonly used to estimate the value of inventory on hand at the end of an accounting period and the cost of goods sold during the period. This method assumes that inventory purchased or manufactured first is sold first and newer inventory remains unsold.

First-In, First-Out Inventory Method First-In, First-Out (FIFO) is one of the methods commonly used to estimate the value of inventory on hand at the end of an accounting period and the cost of goods sold during the period. This method assumes that inventory purchased or manufactured first is sold first and newer inventory remains unsold.

FIFO First in first out explained diagram

Problem analysis diagram

Root Cause Analysis diagram is used to analyze the root causes of factors that influence the problem. It helps to identify the root causes for a factor and then propose possible corrective actions. A diagram is constructed separately for each high priority factor.

Finding Solutions. A problem tree analysis is a pictorial representation of a problem, its causes and its consequences. This analysis tool helps the project team get a quick glance of how a range of complex issues contribute toward a problem and how this problem branches out into a set of consequences.

Problem Analysis. Funded projects are usually proposed to address and/or solve identified problems. Problem analysis therefore involves identifying the overriding problem and establishing the causes and effects related to that problem.

Problem analysis diagram diagram

Lean Six Sigma Project Types Diagram

It’s important to know what kind of Lean Six Sigma project you’re considering. These are 5 classic project types to help you decide. If you’re looking to conduct a Green Belt or a Black Belt project, then you should be working on a Process Improvement Project.

The focus here is on four kinds of “trees” or hierarchical diagrams that become part of many Six Sigma projects: Cause-and-effect diagrams Y-to-x flowdown diagrams Functional analysis diagrams Abstraction diagrams (KJ or affinity)

The focus here is on four kinds of “trees” or hierarchical diagrams that become part of many Six Sigma projects: Each of these trees has a specific thrust and strength that can be surprisingly challenging to capture when a project team tries to build one or more of them.

Lean Six Sigma Project Types Diagram diagram

Waste Iceberg Diagram

Loading… The Free Iceberg PowerPoint Diagram is a concept diagram slide for the success theory of achieving objectives. The template contains the iceberg illustration to present the performance and progress of an individual or the company.

The Iceberg PowerPoint template includes: 10 iceberg diagrams over various background layer stripes. We designed also a lighter version of outline iceberg that is more subtle illustration, in case you want your slides to be less eyecatching. This format is also better if you want to print the presentation.

Another case where the iceberg diagram can be used is product cost illustration. Manufacturing cost takes 15% of all expenditures, whilst project, research, tests and transport cost – another 85%. Another area where iceberg hidden levels of metaphor can be used is system thinking.

Waste Iceberg Diagram diagram

Kaizen Continuous Improvement Approach

What is Kaizen? Kaizen is an approach to creating continuous improvement based on the idea that small, ongoing positive changes can reap significant improvements. Typically, it is based on cooperation and commitment and stands in contrast to approaches that use radical or topdown changes to achieve transformation.

What is Continuous Improvement (Kaizen)? Kaizen is a Lean manufacturing tool that improves quality, productivity, safety, and workplace culture. Kaizen focuses on applying small, daily changes that result in major improvements over time. Kaizen first surfaced during the effort to rebuild Japan after World War II.

In all, the process suggests a humanized approach to workers and to increasing productivity: “The idea is to nurture the company’s people as much as it is to praise and encourage participation in kaizen activities.” Successful implementation requires “the participation of workers in the improvement.”

Kaizen Continuous Improvement Approach diagram

Seven Forms of Waste

When a facility produces too much of a product, it is a form of waste. Even if the product does eventually sell, it causes certain types of waste. For example, if you have too much of a product, it needs to be stored in a warehouse, which is wasting space.

When speaking about waste, lean experts usually refer to seven specifically. These include: transportation, inventory, motion, waiting, over processing, overproduction, and defects. Elimination of these seven kinds of waste can help companies reduce costs, increase employee engagement and customer happiness, and increase profits.

The waste of inventory involves storing products or materials that are not needed at this time. Excess inventory results in a waste of space, and it wastes the cost associated with the physical inventory. Although it is a significant concern in manufacturing, it occurs in other sectors as well.

Seven Forms of Waste diagram

Kaizen Design Principles

Please try again later. There are 5 Fundamental KAIZEN™ Principles that are embedded in every KAIZEN™ tool and in every KAIZEN™ behavior. The 5 principles are: Know your Customer, Let it Flow, Go to Gemba, Empower People and Be Transparent.

The kaizen methodology works at constant improvements through the elimination of waste. It’s been around in Japan since after World War II, though influenced by quality management ideas from the United States. It’s part of The Toyota Way, which is a set of principles that support the company’s management approach to production.

When used in the business sense and applied to the workplace, kaizen refers to activities that continuously improve all functions and involve all employees from the CEO to the assembly line workers. It also applies to processes, such as purchasing and logistics, that cross organisational boundaries into the supply chain.

Kaizen Design Principles diagram

Process Management –DMAIC Approach – Define Measure Analyze Improve Control

The DMAIC improvement cycle is the core tool used to drive Six Sigma projects. However, DMAIC is not exclusive to Six Sigma and can be used as the framework for other improvement applications. DMAIC is an abbreviation of the five improvement steps it comprises: Define, Measure, Analyze, Improve and Control.

The DMAIC methodology has its roots in the PDSA (“plan, do, study, act”) cycle developed by statistician Walter A. Shewhart at Bell Laboratories in the 1930s. But the technique as we know it today has been shaped by some of the largest organizations in the world such as Toyota, Motorola, GE, and Ford Motor Company.

Here are 4 key guidelines: Make sure there is potential to reduce lead time or defects while resulting in cost savings or improved productivity Once you’ve selected a good project, you and your improvement team can apply DMAIC to dig into process issues and deliver quantifiable, sustainable results. Now, on to the DMAIC process!

Process Management –DMAIC Approach – Define Measure Analyze Improve Control diagram

Lean Supply Chain Management Diagram

Lean is an approach to supply chain management that originated with Toyota, which is why you may hear it referred to as the Toyota Production System (TPS). The idea behind Lean is that you use the least amount of time, effort, and resources by maintaining smooth and balanced flow in a supply chain.

Learning Points •Lean supply chain management represents a new way of thinking about supplier networks •Lean principles require cooperative supplier relationships while balancing cooperation and competition •Cooperation involves a spectrum of collaborative relationships & coordination mechanisms

This means creating new parts and paying for the labor associated with the repair, not to mention the inconvenience caused to the customer. Lean vs agile supply chain is really the difference in emphasis. Agile supply chain management focuses on the changing environment of business while lean supply chain is focused on quality control.

Lean Supply Chain Management Diagram diagram

Inventory Management Process

Inventory management refers to the process of ordering, storing, and using a company’s inventory. These include the management of raw materials, components, and finished products as well as warehousing and processing such items. For companies with complex supply chains and manufacturing processes,…

Inventory management refers to the process of ordering, storing, and using a company’s inventory. These include the management of raw materials, components, and finished products, as well as warehousing and processing such items.

1. First, you need to identify the inventory management workflow. Get yourself clear on each specific process by asking workmates and people who are in charge. It’s better to clarify who is responsible for which step and what documents need to prepare when you need to stock in or get products out. 2.

Inventory Management Process diagram

Business Improvement Framework

The following diagram shows an approach to business improvement. Start with strategy and business case, i.e. understand your objectives and formulate what needs to be improved. Proceed to the asis state or current state of the process / business that needs improvement. Create a future state view of how it is out to be. Create a blue print or a roadmap. Proceed with the implementation and the roll out of the change. Track progress and evaluate the solution. Proceed back to the first step in the continuous improvement cycle.

Business Improvement Framework diagram

Cycles of continious improvement

“5 on 5” The 5 Step Continuous Improvement Cycle 1 Identify the target process 2 Organize and empower an improvement team 3 Describe the issues, concerns or opportunity 4 Collect current performance data 5 Create a process map More …

The Continuous Process Improvement Model. Among the most widely used tools for the continuous improvement model is a fourstep quality assurance method—the plandocheckact (PDCA) cycle: Plan: Identify an opportunity and plan for change. Do: Implement the change on a small scale.

Updated November 18, 2019. A continuous improvement plan is a set of activities designed to bring gradual, ongoing improvement to products, services, or processes through constant review, measurement, and action. The Shewhart Cycle (also known as the Delming Cycle or PDCA, which stands for PlanDoCheckAct), or an approach called Kaizen, …

Cycles of continious improvement diagram

Operations Improvement Strategy Diagram

10 Steps To An Effective Manufacturing Operations Management Strategy. Overcoming the challenges of making companywide manufacturing operations more customer driven needs to start with a clear definition of what success looks like. Having accurate, realtime production visibility improves product quality, order accuracy …

In other words, there are at least four different ways to achieve operational excellence through process redesign. A redesign strategy consists of a certain configuration of best practices that are to be applied or avoided, as illustrated in Figure 1.

Thus, operations management is an integral part of an organization’s strategy. Strategy can be considered to exist at three levels in an organization (see Table 2.1): ●Corporate level strategy: Corporate level strategy is the highest level of strategy. It sets the longterm direction and scope for the whole organization.

Operations Improvement Strategy Diagram diagram

Lean Business Agility Framework

Lean business agility is a framework that helps organizations operate in a manner that maximizes their efficiency and effectiveness. This lesson provides a highlevel overview of the things that characterize an agile organization. Imagine what it would be like to run a Fortune 500 company by making it up as you went along.

Business Agility 1 SAFe 5.0 – Your Operating System for Business Agility. … 2 Agile Product Delivery. … 3 Enterprise Solution Delivery. … 4 Lean Portfolio Management. … 5 Organizational Agility. … 6 Continuous Learning Culture. … 7 LeanAgile Leadership. … 8 Measure and Grow. … 9 Summary. … 10 Learn More. …

The road to real business agility is long and neverending. The SAFe Business Agility Assessment helps enterprises understand where they are on their journey and reminds them to celebrate the small successes along the way. It is built directly around the seven core competencies; each competency is further split into the three competency dimensions.

Lean Business Agility Framework diagram

Process Management

Process Management – Business Process Management – BPM – Process Management Diagram – Business Process Management model is a stream within business management that focuses on the management of company’s processes. Essentially, BPM views a business through the eyes of the process, i.e. all activities are processes in one way or another.

Process Management is about active control of the business activities and involves process mapping, KPI and metrics identification, endtoend view and oversight. The key process management steps include process design, process implementation, process enactment and diagnosis (analysis)

process management

Process Management diagram

Kaizen A3 Tool

Kaizen A3 – Kaizen A3 Analysis – Kaizen One Page Problem Solving Tool – Kaizen problem solving tool – Kaizen template – Kaizen A3 Framework – Kaizen A3 is a lean six sigma problem solving tool, which allows to quickly identify the problem, analyze the issues and provide recommendations and action plan with identified owners.

This Lean Six Sigma A3 method was designed as a workshop tool, allowing a work group to stay focused on the problem. Usually, within a span of a day, often within 3 hours, a team can work through a difficult problem and come up with an actionable list of recommendations. All of this fits into 1 page, hence the name – A3.

kaizen a3

Kaizen A3 Tool diagram