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Process Thinking Process Variation Facts, Figures, Data Define, Measure, Analyze, Improve, Control 8 Key Tools - Linked and Sequenced Statistical Tools Minitab Critical Few Variables
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Topics of Non-Manufacturing Projects
• • • • • Billing Energy Reduction Engineering Environmental Finance & Accounting Human Resources Information Technology Internal Audits Inventory Reduction Legal • Logistics Transportation • Customer Service • Maintenance • Planning and Scheduling • Product Design • Purchasing • QC Lab • Safety • Sales • Shipping
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Increase process yield $300k Increase process capacity $400k Increase dryer throughput $130k Reduce process downtime and scrap $320k Reduce caustic use of Process Z $2000k Material loss: Reduce scrap & increase yield $150k Reduce wet milling operations costs $300k
Six Sigma
What It is How It Affects Human Resources
Ronald D. Snee K. W. Tunnell Consulting November 13, 2001
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What is Six Sigma ?
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Measure of how well a process is performing - Six Sigma process produces 3.4 defects per million opportunities - Most companies are at 3-4 sigma level Philosophy of reducing defects so we can improve customer satisfaction and reduce costs Business Strategy that increases process performance resulting in enhanced customer satisfaction and improved bottom line ($$).
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8 Key Six Sigma Tools
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Maps and Metrics Cause and Effect Matrix
Gage R&R Study
Capability Analysis Failure Mode and Effects Analysis
Multi-Vari Analysis
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What is Six Sigma?
INITIATIVE METHODS & TOOLS
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Improvement Breakthrough Systematic, Focused Approach Right Projects - Linked to Business Goals Right People - Selected & Trained Project Management - Management Reviews Sustaining Gains - Identify New Projects Right Results - Process & Financial($$)
ROLES OF LEADERS
Management Team
Master Black Belt Green Belt Functional Groups HR, Finance, IT Engg, QA, etc.
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Project Champion
Black Belt
and
ement Strategy
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Projects in Human Resources
• Reduce cycle time on hiring process • Increase “hit rate” on job applicants • Employee turnover reduction • Overtime reduction • Reducing staffing shortages • Cycle Time Reduction for
Design of Experiments Control Plans including Statistical Process Control
Advanced tools are used as needed to speed up improvement
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Some Manufacturing Black Belt Projects
• Phase 0: Process Definition • Phase I: Process Measurement • Phase II: Process Analysis • Phase III: Process Improvement • Phase IV: Process Control