First year project rev
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First year project rev

First year project rev

AH BEE GOH

19 MARCH 2011

2 April 2011


Title

Presentation title

TITLE

The dependency and necessity on twin forces; ROFO model and KNOWLEDGE COMPETENCY to close the gap -execute Lean Sigma strategy


First year project rev

F1 AND F2 FULFILLED

F1-LACK OF KNOWLEDGE

GAP

GAP CLOSED

F2-NO OWNERSHIP OF

TOTAL PROCESS

FIG. 4.0-2

Presentation title


Application of f1 and f2 forces to execute lean sigma

Presentation title

APPLICATION OF F1 AND F2 FORCES TO EXECUTE LEAN SIGMA

F1- KNOWLEDGE COMPENTENCY

Lean sigma

F2-ROFO MODEL

FIG. 4.0-2


First year project rev

Presentation title

Bloom taxanomy

& COP

Knowledge

competency

Learning systems

Managers

Professionals

Supervisors

and technicians

Production workers

Level 6

Level 5

Level 4

Level 3

Level 2

Level 1

define

Nonaka model

Action learning

Training procedure

Sitting with Nellie

F1

Hypothesis/ ANOVA

measure

0ne piece flow

Takt time

Lean sigma

Kanban pull

control

7 waste removal

5S

Value stream mapping

Visual control

SPC

Bloom taxanomy

& COP

analysis

improvement

F2

R O F O


Survey questions and interview

Presentation title

SURVEY QUESTIONS AND INTERVIEW

  • SURVEY QUESTIONS.doc

  • Interview on Willingness and ability.ppt


First year project rev

Presentation title

Knowledge competency

Level 6

Level 5

Level 4

Level 3

Level 2

Level 1

Learning systems

Knowledge workers

Nonaka model

Action learning

Training procedure

Sitting with Nellie

F1

Managers

Professionals

Production workers

technicians

Knowledge competency

Fig.7.2b


First year project rev

Presentation title

R

R

O

R

OWNERSHIP

RESPONSIBILTY

R

F2

Ownership of total process

O

F

ON- TIME CORRECTIVE

ACTION

FOCUS


First year project rev

Presentation title

define

measure

Hypothesis/ ANOVA

0ne piece flow

Takt time

Lean sigma

Kanban pull

control

5S

7 waste removal

SPC

Value stream mapping

Visual control

analysis

improvement


Definition of rofo

Presentation title

DEFINITION OF ROFO

  • ROFO- is a model to develop self – internalisation and motivation to own total process with the objective to execute tasks/ strategies successfully and on-time.

  • It stands for;

    • R- responsibility.

    • O- ownership.

    • F- focus.

    • O- on-time corrective action.

  • In the ROFO model , there is a fine difference between responsibility and ownership.


Definition of knowledge competency

Presentation title

DEFINITION OF KNOWLEDGE COMPETENCY

  • The ability of the knowledge worker to apply using a combination of skills / experience, knowhow to execute a task successfully.

experience

knowhow

ability

analytical

On – the job

skills

Problem- solving

managerial


Definition of lean

Presentation title

DEFINITION OF LEAN

  • It is a systematic approach to identifying and eliminating waste through continuous improvement, flowing the product at the pull of the customer in pursuit of perfection.

    From; National Institute of Standards and technology Manufacturing Extension Partnership’s Lean Network

    ( Practioner’s guide to Statistics and Lean Six Sigma for process improvements).


Definition of 7 wastes

Presentation title

DEFINITION OF 7 WASTES

  • Over- production- producing items earlier or in bigger quantities than needed by customers. The more you produce the more you will generate wastes such as more manpower is needed and more transportation and storage areas etc.

  • Waiting- Any waiting is considered a waste such as waiting for materials or watching to serve automated machine.

  • Transportation- moving work in process (WIP) from one location to another.

  • Over processing and incorrect processing- Taking unneeded steps to processthe parts- Inefficient processing due to poor tools or jigs.


Definition of 7 wastes1

Presentation title

DEFINITION OF 7 WASTES

5. Excess inventory- Excess raw materials, WIP and finished goods which give rise to obsolescence.

6. Unnecessary motion- Employees have to move in an unnecessary manner which will not add any value .

7.Defects and quality problems.- Producing defective parts which have to be scrapped or reworked.


Elimination of 7 wastes

7 Wastes In Manufacturing

Over

Production

Unnecessary

motion

Over

Processing

Rejects and

Defects

Seven Wastes

Inefficient

Transportation

Waiting

Times

Excess

inventory

Presentation title

ELIMINATION OF 7 WASTES


Definition of six sigma in statistical meaning

Presentation title

DEFINITION OF SIX- SIGMA IN STATISTICAL MEANING

With 4.5 sigma at the mean it achieves 3.4 defects per million with 25% design margin


First year project rev

Presentation title

DEFINITION OF SIX- SIGMA IN STATISTICAL MEANING

With 6 sigma at the mean it achieves 2 defects per billion with 50% design margin


Definition of dmaic

Presentation title

DEFINITION OF DMAIC

  • DMAIC stands for ;

    • Define the problem- understand the requirements of customer and what goals we want to achieve.

    • Measure the the existing process and collect relevant data.

    • Analyse the current performance to isolate the problem. Through analysis ( statistical and qualitatively) , formulate and test hypothesis about the root cause.

    • Improve the problem by selecting the solution based on the ‘ analysis “ stage.

    • Control the improved process to ensure the targets are met


First year project rev

Presentation title

Define

Measure

Control

Analyse

Improve

yes

no

Measure sys

effective ?

no

yes

no

yes

Problem exists

In lean cells?

Process capable

?

Sustainable ?

Process capable

?

yes

no

no

yes

No- close the project

Remove variation completely

Close the project

Close the project


First year project rev

Presentation title

Thank you very much for your attention.

Any questions?


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