Escolar Documentos
Profissional Documentos
Cultura Documentos
Introduction
"The design(s) and/or concept(s)shown in this presentation
are the confidential property and invention of CTS Corporation Automotive
Course Objectives
Understand the CTS Lean Six Sigma Journey
Understand and apply the principles of Lean and Six Sigma
Waste Reduction
Variation Reduction
Basic Algebra
Process Knowledge in your area
Broad Familiarity with CTS businesses and processes
Basic Computer Skills
Spreadsheets
Word Processing
Graphics
Charting
Agenda
Day 1
Course Guidelines
Introduction to Lean Six Sigma
Define
Day 2
Measure
Day 3 and 4
Analyze
Day 5
Improve
Day 6
Control
Replicate
Closure
"The design(s) and/or concept(s)shown in this presentation
are the confidential property and invention of CTS Corporation Automotive
Introduce Yourselves ..
Name
Business Unit / Function
Prior Exposure to Lean Six Sigma
Expectations from Class
Introduction to
Lean Six Sigma
"The design(s) and/or concept(s)shown in this presentation
are the confidential property and invention of CTS Corporation Automotive
Brainstorm .
What do Lean and Six Sigma mean to you ..
Problem
ProblemSolving
Solving
Consistent
ConsistentApproach,
Approach,
Common
Language
Common Language&&
Tools
Tools
Define
Define
Measure
Measure
Analyze
Analyze
Improve
Improve
Control
Control
Strategic
StrategicEnable
Enable
Execution
of
Execution ofStrategy
Strategy
Alignment
Alignmentwith
withStrategy
Strategy &&Financial
FinancialGoals
Goals
Focus
Focuson
oncore
coreprocesses,
processes,value
valuestreams
streams
Results:
Results:Successful
SuccessfulStrategy
Strategyexecution
execution&&financial
financialperformance
performance
History
1733
1900s
1990s
Leadership Perspectives
The big myth is that Six Sigma is about quality control and
statistics. It is that but its a helluva lot more. Ultimately it drives
leadership to be better by providing tools to think through tough
issues.. It can turn a company inside out, focusing outward
on the customer.
-Jack Welch, Jack: Straight from the Gut
Six Sigma is one of the best things we have ever done. . Since
the inception of the program in September 1999, weve saved or
avoided spending a total of $1.4 billion, completed 7,500 projects
and trained 6,000 belts with almost a million hours of training ..
- Tim Solso, CEO, Cummins, upon receiving Six Sigma
CEO of the Year Award, 2007
FTY CTS
CTS TOOL
FTY
TOOL ROOM
ROOM
120%
120%
18.0%
100%
80%
16.0%
% of Parts with
Deformations
100%
60%
80%
40%
60%
20%
14.0%
12.0%
17.6%
10.0%
8.0%
6.0%
40%
0%
4.0%
20%
0.0%
0.0%
2.0%
Current Process
Manual Pickoff
0%
Molding 2 Shot Friction Lever Sort Costs
700-62-002 / 702-62-002 / 705-62-001
June 2009 - June 2010
Jan
Target (%) 100%
Actual (%) 85%
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
97%
94%
0.70
0.74
88%
96%
25of95
24of83
3/26
3/74
2/59
100
3/46
80
$ (K)
6of40
Feb
100%
60
50
2
1
$84
40
20
0
$0
Current Cost
Future Cost
40
30
20
60
Defects per
Million
Opportunities
Long Term
Yield
308,537
69.15%
66,807
93.32%
6,210
99.38%
233
99.98%
3.4
LSL
Defects
USL
Acceptable
Defects
99.99966%
=7
-6s
-5s
-4s
-3s
-2s
-1s
68.26%
95.44%
99.73%
99.9937%
99.999943%
99.9999998%
History of Lean
1990: Womack, Jones & Roos (The Machine that Changed the
World) coin the word Lean to define Toyota Production System
8 Wastes
Defects
Overproduction
Waiting
The Worst!
Drives Waste in Other Areas
Examples of Waste
Forms of Waste
Manufacturing
Office
Defects
Invoice errors
Overproduction
Waiting
Excessive WIP
Non-utilized talent
Transportation
Inventory
Motion
Extra Processing
Additional machining ??
5 Principles of Lean
Define
Measure
Analyze
Design
Verify
DFSS includes rich and advanced tool kit that can be aligned with product
development process
QFD, Design FMEA, Axiomatic Design, Design of Experiments (DOE), Theory of
Inventive Problem Solving, etc.
DFSS can be aligned with pre-existing toll gate processes
Prevention
Training
Systems & Planning
Preventive Maintenance, etc
Appraisal
All Inspection
Test Equipment Calibration
Audits
Internal
External
Customer Complaint processing
Returned goods processing & replacement
Legal / Settlement costs
Benefits
Improves quality and efficiency
Strengthens culture
Helps develop a common
approach to problem solving
Pitfalls
Lack of leadership support will cause it
to fail
Over emphasis on tools versus
methodology
No clear alignment with operational
goals
Avoid Six Sigma for Six Sigmas sake
2.
3.
Identify and train Black Belts in DMAIC and Design of Six Sigma.
4.
5.
PERFORMANCE IMPROVEMENT
INFRASTRUCTURE
Teach
Support
Consult
Measure
Measure
Analyze
Improve
Control
Executive
ExecutiveSteering
SteeringTeam
Team
Champion
Champion
Functional
FunctionalManager
Manager
Finance
Finance
Process
ProcessOwner
Owner
Master
MasterBlack
BlackBelt
Belt
Green Belt
Black Belt
Green Belt
Yellow Belt
Yellow Belt
Communication
and Coordination
Vision
Priority
Path
Define
An
An internal
internal consultant,
consultant, trainer,
trainer, and
and expert
expert
3.
4.
5.
6.
7.
2.
Provide financial valuation and validation support during Define Phase through
project closure
3.
Provide updated financial forecasts whenever there is a change in the project goal,
expected results, timeline, or valuation assumptions.
4.
Provide financial forecast by month for the first 12 months, and an annualized
amount thereafter
5.
Track and report project actual financial impact (beginning with the implementation
of project solutions
6.