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Lean Process And Six Sigma Corporate Training Materials

Lean Process And Six Sigma Corporate Training Materials. Module One: Getting Started. Quality means doing it right when no one is looking. Henry Ford. Welcome to the Six Sigma workshop. The last couple of decades companies have embraced Six Sigma to generate

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Lean Process And Six Sigma Corporate Training Materials

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  1. Lean Process And Six Sigma Corporate Training Materials

  2. Module One: Getting Started Quality means doing it right when no one is looking. Henry Ford • Welcome to the Six Sigma workshop. • The last couple of decades companies • have embraced Six Sigma to generate • more profit and greater savings. So • what is Six Sigma? • Six Sigma is a data-driven approach for eliminating defects and waste in any business process.

  3. Workshop Objectives

  4. Module Two: Understanding Lean Six Sigma is the most important training thing we have ever had. It’s better than going to Harvard Business School. Jack Welch • Lean and Six Sigma are buzz-words we hear in business all of the time. Before we get started, let’s make sure we all understand just what we mean by “lean” and “Six Sigma”.

  5. About Six Sigma

  6. About Lean

  7. History Behind Lean

  8. Toyota Production Systems

  9. The Toyota Precepts

  10. Module Two: Review Questions • Six sigma equates to: • 1.4 DPMO • 2.4 DPMO • 3.4 DPMO • 4.4 DPMO • Which letter is used Sigma capability? • S • C • Y • Z

  11. Module Two: Review Questions • Which of the following actions is not so typical for the lean process? • Eliminating waste • Eliminating people • Reducing costs • Shortening time cycles • Which of the following is not an example of lean process? • Reduced inventory • Increasing overall productivity • Decreased defects • Skipped details in reports

  12. Module Two: Review Questions • Which car company’s production system is related with early usage of ‘lean manufacturing’? • Mercedes-Benz • Toyota • General Motors • BMW • Besides “The machine that changed the world”, which book also shaped the ideologies of ‘Lean’? • “Lean process” • “Lean manufacturing” • “Lean thinking” • “Lean world”

  13. Module Two: Review Questions • What was the original name of TPS? • Just in time production • Just right production • Just precise production • Just appropriate production • What is the last step of TPS? • Defining value of your product • Striving for perfection • Making only what the customer orders • Studying the flow of your product

  14. Module Two: Review Questions • What does GENCHI GEBUTSU mean? • Wait and see • Come and see • Go and see • Look and see • Committing to education and development is especially important for: • Respect • Kaizen • Challenge • Teamwork

  15. Module Two: Review Questions • Six sigma equates to: • 1.4 DPMO • 2.4 DPMO • 3.4 DPMO • 4.4 DPMO • Which letter is used Sigma capability? • S • C • Y • Z

  16. Module Two: Review Questions • Which of the following actions is not so typical for the lean process? • Eliminating waste • Eliminating people • Reducing costs • Shortening time cycles • Which of the following is not an example of lean process? • Reduced inventory • Increasing overall productivity • Decreased defects • Skipped details in reports

  17. Module Two: Review Questions • Which car company’s production system is related with early usage of ‘lean manufacturing’? • Mercedes-Benz • Toyota • General Motors • BMW • Besides “The machine that changed the world”, which book also shaped the ideologies of ‘Lean’? • “Lean process” • “Lean manufacturing” • “Lean thinking” • “Lean world”

  18. Module Two: Review Questions • What was the original name of TPS? • Just in time production • Just right production • Just precise production • Just appropriate production • What is the last step of TPS? • Defining value of your product • Striving for perfection • Making only what the customer orders • Studying the flow of your product

  19. Module Two: Review Questions • What does GENCHI GEBUTSU mean? • Wait and see • Come and see • Go and see • Look and see • Committing to education and development is especially important for: • Respect • Kaizen • Challenge • Teamwork

  20. Module Three: Liker’s Toyota Way Do you value practices, or do you practice values? Anonymous • In this module we will look closer at Toyota’s philosophies that have become a spiritual pinnacle of modern manufacturing. “The Toyota Way” is a book about the 14 principles that drive Toyota’s culture.

  21. Philosophy

  22. Process

  23. People and Partners

  24. Problem Solving

  25. Module Three: Review Questions • How many principles are in Dr. Jeffrey Linker’s book “The Toyota Way”? • 6 • 7 • 10 • 14 • In Toyota’s vision, what’s the most important thing for a company’s philosophy? • To be original • To be verified • To be long-term • To be safe

  26. Module Three: Review Questions • According to 3rd principle, what kind of system should you use to avoid overproduction? • Push • Pull • Drag • Scratch • According to 7th principle, what kind of control should we use to make all the problems visible? • Digital • Classical • People • Visual

  27. Module Three: Review Questions • According to 4th principle (Heijunka), we should work like: • Ants • Bees • Turtles • Rabbits • Which principles refer to people and partners? • 1, 2, 3 • 5, 6, 7 • 9, 10, 11 • 12, 13, 14

  28. Module Three: Review Questions • According to one of the principles, how do you respect the extended network of partners and suppliers? • By awarding them • By criticizing them • By including them in more company’s activities • By challenging them • Which of the following is not necessary for a good leader? • Understanding the work • Leaving the philosophy • ‘Teaching’ that philosophy to others • Upgrading that philosophy

  29. Module Three: Review Questions • What are the last principles related to? • Problem solving • Profit • Management • Personal development • What is Kaizen? • Continuous work • Continuous problem solving • Continuous improvement • Continuous earnings

  30. Module Three: Review Questions • How many principles are in Dr. Jeffrey Linker’s book “The Toyota Way”? • 6 • 7 • 10 • 14 • In Toyota’s vision, what’s the most important thing for a company’s philosophy? • To be original • To be verified • To be long-term • To be safe

  31. Module Three: Review Questions • According to 3rd principle, what kind of system should you use to avoid overproduction? • Push • Pull • Drag • Scratch • According to 7th principle, what kind of control should we use to make all the problems visible? • Digital • Classical • People • Visual

  32. Module Three: Review Questions • According to 4th principle (Heijunka), we should work like: • Ants • Bees • Turtles • Rabbits • Which principles refer to people and partners? • 1, 2, 3 • 5, 6, 7 • 9, 10, 11 • 12, 13, 14

  33. Module Three: Review Questions • According to one of the principles, how do you respect the extended network of partners and suppliers? • By awarding them • By criticizing them • By including them in more company’s activities • By challenging them • Which of the following is not necessary for a good leader? • Understanding the work • Leaving the philosophy • ‘Teaching’ that philosophy to others • Upgrading that philosophy

  34. Module Three: Review Questions • What are the last principles related to? • Problem solving • Profit • Management • Personal development • What is Kaizen? • Continuous work • Continuous problem solving • Continuous improvement • Continuous earnings

  35. Module Four: The TPS House Toyota is as much a state of mind as it is a car company. USA Today • If TPS is a mindset, then what’s holding it all together, is the TPS House. • In this module we look at the TPS house, the blueprint for a Lean Enterprise that has become one of the most recognizable symbols of modern manufacturing.

  36. The Goals of TPS

  37. The First Pillar: Just In Time (JIT)

  38. The Second Pillar: Jidoka (Error-Free Production)

  39. Kaizen (Continuous Improvement)

  40. The Foundation of the House

  41. Module Four: Review Questions • Which of the following is not a type of waste that has to be eliminated according to TPS? • Overburden or stress in the system • Inconsistency • Energy surplus • Muda • What is the first rule to TPS? • All work shall be highly specified • All work shall be highly profitable • All work shall be highly simplified • All work shall be highly exclusive

  42. Module Four: Review Questions • In context of TPS house, JIT is: • The roof • A wall • A pillar • Foundation • JIT doesn’t help reducing: • Inventories • Holding costs • Warehousing • Production costs

  43. Module Four: Review Questions • What is Jidoka? • Risk-free production • Error-free production • Tax-free production • Unlimited production • What happens if the supervisor cannot complete the job within the given amount of time? • Nothing, except the production is late • He must speed the process up, damaging the quality • The line goes too slow • The line will be stopped

  44. Module Four: Review Questions • What is the first phase of Kaizen? • Analyzing the process • Identifying an opportunity • Planning future • Developing a solution • According to Kaizen, if a mistake happens, you should: • Analyze it deeply and think through the solution • Leave it aside for a couple of days to think it through • Correct it right away • Decide is it important to be fixed at all

  45. Module Four: Review Questions • What does Heijunka mean? • Scaling • Grading • Measuring • Leveling • Which of the following are approaches in lean leveling? • Demand and production • Consumption and profiting • Simple and complex • Local and global

  46. Module Four: Review Questions • Which of the following is not a type of waste that has to be eliminated according to TPS? • Overburden or stress in the system • Inconsistency • Energy surplus • Muda • What is the first rule to TPS? • All work shall be highly specified • All work shall be highly profitable • All work shall be highly simplified • All work shall be highly exclusive

  47. Module Four: Review Questions • In context of TPS house, JIT is: • The roof • A wall • A pillar • Foundation • JIT doesn’t help reducing: • Inventories • Holding costs • Warehousing • Production costs

  48. Module Four: Review Questions • What is Jidoka? • Risk-free production • Error-free production • Tax-free production • Unlimited production • What happens if the supervisor cannot complete the job within the given amount of time? • Nothing, except the production is late • He must speed the process up, damaging the quality • The line goes too slow • The line will be stopped

  49. Module Four: Review Questions • What is the first phase of Kaizen? • Analyzing the process • Identifying an opportunity • Planning future • Developing a solution • According to Kaizen, if a mistake happens, you should: • Analyze it deeply and think through the solution • Leave it aside for a couple of days to think it through • Correct it right away • Decide is it important to be fixed at all

  50. Module Four: Review Questions • What does Heijunka mean? • Scaling • Grading • Measuring • Leveling • Which of the following are approaches in lean leveling? • Demand and production • Consumption and profiting • Simple and complex • Local and global

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