Professional Documents
Culture Documents
ENTERPRISE
Integrating Lean
& Six Sigma
L E A N
ENTERPRISE
SHAPE
SHAPEVISION
VISION
CREATE
CREATENEED
NEED
Flow
Intermediate
MAKE
MAKEIT
ITLAST
LAST
MOBILIZE
MOBILIZECOMMITMENT
COMMITMENT
Advanced
Kan Ban
Stop at Abnormalities
Standard Work
Foundation
5S
TAKT Time
Value Stream Mapping
Sort
Supermarket
Sweep
Standardize
Kitting
Self Discipline
Sustain
Level Loading
Pull Production
Measure
Analyze
Improv
e
Control
SUSTAIN THE SOLUTION
L E A N
ENTERPRISE
Six Sigma
Order Fulfillment
Inventory
NPI
Cash/Revenue
Billing Accuracy
Service Delivery
Cycle Time
Sales Force Effectiveness
Installation
Lean
Order Fulfillment
Inventory
NPI
Cash/Revenue
Billing Accuracy
Service Delivery
Cycle Time
Sales Force
Effectiveness
Installation
L E A N
ENTERPRISE
Define
Measure
Analyze
Improve
Control
Sub-Y Selection
-Distance Traveled (Ft)
-Floor Space (Ft2)
-# of Touches
-Mat. Handling/Ergo (#)
-Quality Defects (DPMO)
-RIP/WIP/FG Inv. (ICV$)
-Cycle Time (Minutes)
-Lead Time (Minutes)
EHS Review
Link to Example
FMEA
Link to Example
P-R Analysis
Link to Example
P-Q Analysis
Link to Example
Pre-work/Kick-off
Checklists Complete
Link to Checklist
Gage R&R
Link to Example
Pugh Matrix
Link to Template
Target Sheet
(New Process)
Link to Example
Standard Worksheet
(New Process)
Link to Example
Update/Close Project
In Six Sigma Works
Standard Worksheet
(Existing Process)
Pitchout Checklist
Complete
Link to Example
Link to Example
Link to Example
Link to Example
Link to Example
Link to Checklist
Link to Works
Link to Quickplace
Document Lessons
Learned
Link to Example
SOPs/OMSs Updated
Link to Example
Target Sheet
(Existing Process)
Link to Example
Solution Implemented
& Verified
AWO
Link to Works
L E A N
ENTERPRISE
Six
SixSigma
SigmaProject
Project#63875
#63875
GSC
GSC--X-ray
X-ray--AMX
AMX
02/04/02
02/04/02 --10/13/02
10/13/02
TEAM MEMBERS:
Project
ProjectDescription:
Description:
Action
ActionWorkout
Workoutto
tomake
make
the
theAMX
AMXBase
BaseBox
Boxsetsetup
upeasier,
easier,quicker,
quicker,&
&
safer
saferall
allwhile
whilereducing
reducing
inventory.
inventory.
GPS MBB
PET Mfg.
PET Mfg.
Gold Seal
CT Mfg.
Reduced
Reducedset-up
set-uptime
timefrom
from20
20minutes
minutesto
to30
30
seconds
seconds
Reduced
Reducedset-up
set-uptime
timevariation
variationfrom
from55minutes
minutesto
to55
seconds
seconds
Reduced
Reducedinventory
inventoryof
ofAMX
AMXBase
Base(2273441)
(2273441)by
by
$130K!
$130K!
L E A N
Define Phase
ENTERPRISE
Define
Define
L E A N
ENTERPRISE
51 Bases On Hand
No Schedule
24 Bases en-route
Coakley
Waukesha
51 Bases On Hand
GEMSMM
Monterrey
3
5
Empty Container
Full Container
# # of Containers at Location
4
A
2
GEMS
No Schedule
30 Bases en-route
No Schedule
6 Bases en-route
MMP
Chicago
15 Bases On Hand
L E A N
Measure Phase
ENTERPRISE
Measure
Measure
Project Y Selection:
The focus of this project is on reducing the setup time of
the base box for the AMX line. The improvement of the
Big Y will positively affect inventory, quality, and EHS.
Before Photos
See pages 6 & 7 for the before photos
documenting the current AMX Base Box Setup situation.
Standard Worksheet
See page 8 for the standard worksheets
displaying the flows of people and material
for the Base Box setup process.
Standard Work Combination Sheet
See page 9 for the Standard Work
Combination sheet detailing the specific steps
required to perform the AMX Base Box Setup.
Target Sheet
See page 10 for the target sheet for this
action workout detailing the baseline
measurements obtained in three key areas:
set-up time, EHS, and quality.
L E A N
ENTERPRISE
Operation
Unload Base
Problem
Actions Taken
Ergonomic & variable task time
issues
Material handling damage
TBD
Step 1
Results
TBD
Step 2
(Sketch)
(Sketch)
L E A N
ENTERPRISE
Operation
Unload Base
Problem
Actions Taken
Ergonomic & variable task time
issues
Material handling damage
TBD
Step 3
Results
TBD
Step 4
(Sketch)
(Sketch)
L E A N
ENTERPRISE
L E A N
ENTERPRISE
L E A N
ENTERPRISE
Date: 2/4/02
Start
Target
1st Day
Changeover/set up (hr,min,sec)
20 Minutes 2 Minutes
# of Internal Steps
# of External Steps
Total # of Steps
16
5
0
0
2nd Day
3rd Day
4th Day
Result
Total Change
L E A N
Analyze Phase
ENTERPRISE
Analyze
Analyze
DPMO: 1,000,000
Performance Objective:
Z st: 6
DPMO: 3
7 Ways Form
See page 11 for the 7 ways form detailing
seven different ways to solve the high set-up
time problem for the AMX Base Box.
L E A N
ENTERPRISE
L E A N
Improve Phase
ENTERPRISE
Improve
Improve
05/31/02
Pugh Matrix
Vital Few Xs: Material Handling techniques; Use of
Crane; Configuration of Container; Internal vs. External
Set-up.
Comments: The Action Workout setting was utilized to
drive solutions in the Improve phase.
L E A N
ENTERPRISE
CTQs
Importance Option 1 Option 2 Option 3 Option 4 Option 5 Option 6 Option 7
20 sec
5
1/5
3/15
3/15
1/5
9/45
3/15
3/15
Ergonomics
5
3/15
9/45
3/15
3/15
9/45
3/15
3/15
NO Crane
5
9/45
9/45
9/45
9/45
9/45
9/45
9/45
Std Height
2
1/2
3/6
3/6
3/6
3/6
3/6
3/6
Safety
5
1/5
3/15
3/15
1/5
9/45
3/15
3/15
Cost
4
3/12
3/12
3/12
1/4
9/36
3/12
1/4
Maintenance
4
3/12
1/4
1/4
1/4
9/36
1/4
3/12
TOTAL
96
142
112
84
258
112
112
L E A N
ENTERPRISE
Date: 2/4/02
Start
Target
20 Min
1st Day
2nd Day
3rd Day
4th Day
Result
2 Minutes Same
1 Min
30 Sec 30 Sec
0 Same
Same
Same
0 Same
Same
Same
Total Change
Changeover/set up (Min)
30 Sec
97% Red.
0
0
100% Red.
100% Red.
# of Internal Steps
# of External Steps
Total # of Steps
16
5
L E A N
ENTERPRISE
L E A N
Control Phase
ENTERPRISE
Control
Control
Process Capability:
Z st: 6
DPMO: 0
L E A N
ENTERPRISE
GEMSMM (Leg 3)
Day
Monday
Thursday
Coakley
Waukesha
Arrive Depart
?
?
?
?
Coakley (4&5)
Empty Container
Full Container
# # of Containers at Location
4
1
GEMSMM
Monterrey
GEMS (4&5)
5:35am
6:45am
7:05am
8:15am
9:05am
10:15am 11:05am
12:15pm 1:05pm
2:15pm
-
6:00am
7:30am
9:30am
11:30am
1:30pm
-
6:20am
7:50am
9:50am
11:50am
1:50pm
-
2
GEMS
MMP (Leg 2)
Day
Legs 1&A
Day
MMP
Monday
Thursday
Coakley
Monday 7:00am
Tuesday 7:00am
Wednesday7:00am
Thursday 7:00am
Friday 7:00am
8:00am
8:00am
8:00am
8:00am
8:00am
12:00pm
12:00pm
12:00pm
12:00pm
12:00pm
2:00pm
2:00pm
2:00pm
2:00pm
2:00pm
MMP
Chicago
Arrive Depart
-
4:00pm
4:00pm
L E A N
8-Feb
8-Feb
8-Feb
8-Feb
8-Feb
8-Feb
TARGET
% COMPLETE
COMPLETION
FW 7
FW 7
FW 7
FW 7
FW 7
FW 7
75%
DATE
ASSIGNED
50%
OWNER
25%
ACTION ITEM
X
X
X
X
X
X
100%
ENTERPRISE
L E A N
ENTERPRISE
Measure:
EHS
Setup Time
Quality
Inventory
Summary of Results
Improvement
Eliminated 16 Pinch Points
Reduced 20 Min. Setup
(~30 Sec)
Eliminated Handling Damage
Eliminated 102 Bases in Cycle
(~$130K)