Lean and Six Sigma

Continuous Improvement
Celestica de Monterrey CMX

WCM PRACTICES:

Six Sigma
Projects

The five
Steps

Kaizen
Events

Daily
Kaizen

Gemba
Walk

People
Engagement

Recognition
program

Self directed
teams

Six Sigma:
Objectives: structured, systematic approach to reduce the variation within the
process/system that causes defects, using tools based on statistical analysis &
data.
Projects:
Green belt projects
Black belt projects
All the projects must have the next bullets:

Definition
Problem definition*
Objective*
Core KPI*
Estimate savings
Team members
Overview process map*
Measure
Process map*
Diagram / Matrix cause and
effect**
Analysis of measure system
Initial process capacity*
FMEA**

** Almost one

Analyze
Data graphic analysis*
Hypothesis proof *
Improve
Y = f(X)
Techniques of problem solutions*
DOE
Poka Yoke
Control
FMEA reviewed*
Control plan*
Transition project plan*
Final report*

* Required element

5S - The five Steps:

Objective: Create an operational excellence culture in all the employees, achieving
the discipline or habit of properly maintaining the correct 5s procedures.
Activities:
House keeping gemba walks
Production and support audits
Fives steps improvement actions (format)
Weekly results are published
Practical training

Daily Kaizen:
Objective: Involve the operating personnel to reduce the waste in their areas,
attacking the low hanging fruits.
Activities:
Each area have a weekly quantity goal
Practical training to do Kaizens
A3 format
Process:
Idea

Lean
Validation

Pilot
execution

Control Stage

Documentation

Replica

Feedback

The daily kaizen projects are focus in the low hanging fruits opportunity areas.

End

Kaizen Events:
Objectives: Eliminate the waste improving the current situation trough the lean
methodology
Projects:
Kaizen Blitz (1-4 weeks)
Structured Kaizen (1-3 months)
All the projects must have the next bullets:

Plan
Introduction and context of the
problem*
Problem Description
Measurable target*
Root cause Analysis
Create implementation plan
Do
Execute the implementation plan
Check
Execute a follow up plan
Validate the implementation

Lean Tools
Yamazumi
Cell design
Standard work
VSM
TPI (Transactional process improvement)
Lean Office.
TPM
Visual management

Act
Document in A3 format
Standardize the improvement

Breakthrough thinking

Gemba Walks:
Objective: Promote Lean culture, management involvement and ownership
Managers participation
Gemba walk format
Gembas in all the areas (Shipping, production, materials, warehouse, test, etc

People Engagement:
Objective: Involve the all the employees of Celestica in the Lean and Six Sigma activities
Weekly KPI review:
Managers review the lean and Six Sigma activities
Monthly Continuous Improvement Event.
Team members present results of lean and Six Sigma activities.
Recognition to the team by Management
Lean and Six Sigma Scorecard
Assess the support and production areas in terms of continuous improvement
involvement
Yearly Continuous improvement symposium
Invite subject expert matter people to talk about Continuous improvement
Conferences
Practical training
Kaizen competition
Recognition

FAR

ASY

MATERIALES

SMT

PRD

5s

50

0.918

2609

20

0.883

1044

41

0.895

2159

35

0.918

1804

12

0.874

709

44.8705

Gembas

AREA

People engagement

Daily Kaizen

7900

10

80

50

75

Kaizen events

75

15

Proyectos Six Sigma

50

150

CI SCORE CARD

PONDERACION

Total

6
7
8
9
10
11
12
13
14
15
16
17

Total

Recognition:
Objective: Motivate and recognize the employees promoting the participation in
lean and six sigma activities.
Activities:
Kaizen points
Catalogue of products (living the brand)
Impulse the employee participation
Evaluation formats for kaizen projects (Daily, Blitz, Structured)
5s recognition each quarter for the best support and production area.

Self directed teams:

Objective: Carry out the procedures, standards, production goals and plans in order
to be an efficient and competitive company.
Description: Group or persons sharing their abilities, knowledge and experience,
committing with the company goals.
Activities:
Reach the goals:
5s
Production rate
Yield
Operating efficiency
Kaizen