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PROGRESS IN IMPLEMENTATION GB TRAINING ONGOING PROJECTS OPERATING PLAN VISION 1,3,5 YEARS NEXT STEPS PROPOSAL FOR MASTER THESIS SUBJECT: QUALITY COST (COPQ) COUNTING AND REPORTING SYSTEM AND PROCEDURES TO DRIVE SIX SIGMA PROJECT SELECTION. AGENDA FOR 6S COUNCIL EUROPE 3.4.2003.

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Agenda for 6s council europe 3 4 2003

PROGRESS IN IMPLEMENTATION

GB TRAINING

ONGOING PROJECTS

OPERATING PLAN

VISION 1,3,5 YEARS

NEXT STEPS

PROPOSAL FOR MASTER THESIS SUBJECT:

QUALITY COST (COPQ) COUNTING AND REPORTING SYSTEM AND PROCEDURES TO DRIVE SIX SIGMA PROJECT SELECTION

AGENDA FOR 6S COUNCIL EUROPE 3.4.2003


Targets 2003 europe

Benefits from 6S projects =1500 000€ (Benefits/costs=3.5)

18 Green belts trained (5 Lahti, 5 Hollola, 2 Laitila, 2 Tooling, 2 Helmond, 2 Pécs)

30 Greenbelt projects finished by 31.12.2003 or 750 000€

6 Black belt projects finished by 31.12.2003 or 750 000€

Training material created for GB and awareness training

Define procedures how individual 6S projects will be reported so that the results can be utilized throughout whole company

TARGETS 2003 EUROPE


6s operationalizing plan europe
6S OPERATIONALIZING PLAN EUROPE

SIX SIGMA VISION

+NEED FOR 6S

TARGETS/

EXPECTATIONS

FOR BB+GB

COST OUT

YIELD…

P

A

6S COUNCIL

CHAMPIONS ON BOARD

MBB NETWORK

GE SUPPORT

C

D

SUPPORT

INFRASTRUCTURE

TARGETS/

EXPECTATIONS

6S+MBB

1st Wave

2 BBs Kim + Wille

Choosing 5 GB’s/Plant

FEEDBACK FROM

GE/Marcel

Present state analysis

Benchmarking

6S council+BBs

RESOURCES

Project selection

Assign high leverage

projects for BBs+GBs

Ensure early wins

DEPLOYMENT

INITIAL PLAN

PROJECTS

TRAINING

GB Training

Awareness training

CAP for BBs

DFSS/DMAIC

Measure progress

MEASUREMENT+

TRACKING

COACHING

MBB coaches + facilitates

BBs + GBs

REPORT TO

6SCOUNCIL+PVI

REPORTING

ASSESSMENT+

REVIEW

Results reported to 6SC

ASSESSMENT

CRITERIA

Reward good results successes

training/project completion

REWARD

EARLY SUCCESS

IMPROVE

DEPLOYMENT PLAN

TRANSLATE

RESULTS

NEXT

PROJECTS


Progress in implementation

21 GB selected (9 Lahti, 5 Hollola, 2 Tooling, 1 Laitila, 3 Helmond, 1 Pécs)

18/21 GB’s have project

GB training material for 1st module created

1st module of GB training 8.-9.4 (Jan Martens/GEP, AK, WV as trainers)

Supporting Kim, Wille, Janna and Johanna

Annual plan created

1-3-5 years vision created

Quality research =>results by 11.4, America+Europe+China next

PROGRESS IN IMPLEMENTATION


Agenda for 6s council europe 3 4 2003

GB PROJECTS Helmond, 1 Pécs)


Ongoing bb projects

Wille Helmond, 1 Pécs)

Vanessa A+B combinations =>testing+analyzing

Jacqueline A+B USW and combinations =>testing+analyzing

A new project is needed

Kim

Foil positioning improvement in Jacqueline window =>Target finished at W17

Starting project: Bright dots in IMD process

Janna

DFSS: 2S IMD Window in Hitchiker

Johanna

DFSS: Implementing SPC

Development team projects 3 large BB projects (Niina)

ONGOING BB PROJECTS


Operating plan
OPERATING PLAN Helmond, 1 Pécs)



Agenda for 6s council europe 3 4 2003

SIX SIGMA CAPABILITY CURRENT STATE ANALYSIS Helmond, 1 Pécs)

Six

Sigma

Excel-

lence

Six Sixma

Institu-

tionalized

No

experi-

ence

Some

experi-

ence

Experi-

ence

DFSS

NOW

1 YEAR

3 YEARS

5 YEARS

DMAIC

CAP

LEAN

SIX

SIGMA

BB


Agenda for 6s council europe 3 4 2003

PROCESSES WHERE 6S HAVE BEEN APPLIED Helmond, 1 Pécs)

Pad

printing

Painting

USW

Bezel

Assembly

SPC

SCM

Injection

molding

IMD

IML

insert

Assembly

DFSS

DMAIC

BB


Agenda for 6s council europe 3 4 2003

INTERNAL FOCUS Helmond, 1 Pécs)

ALSO EXTERNALLY

Important

CTQ alignment with

company goals and

external CTQ’s

SIX SIGMA AT

SUPPLIER/

CUSTOMER

6S-

TRACKER

SOFT-

WARE

Important

Impact of project

CTQ

FLOWDOWN

FROM

COMPANY

GOALS

Important

There are projects

Number of projects

PROJECTS

CHOSEN

BASED

ON FACTS

COPQ

REPOR-

TING AND

SELECTION

CRITERIA

Project scope

  • In addition: Mission critical projects

  • Projects derived directly from goals

PROJECTS

CHOSEN

BASED

ON FEELING OR

EMERGENCY

Project scope

  • In addition: Complete processes, technologies, design and

    verify new processes, SCM, lean, factory level projects

  • Translating results

  • Create and disseminate best practices

Project scope

Single product or

part of simple process

Production processes


Six sigma vision

1-YEAR (2003) – Re-implementation of Six Sigma Helmond, 1 Pécs)

Company level: Beginning 6 BB projects, 30 GB projects, 5 DFSS projects

Simple projects, single product/part of simple processes, production projects, some DFSS projects

Beginning to use Six Sigma metrics and reporting

Individual level: Beginning mainly 1-3 project experience for GB’s and BB’s, people need lot of support and coaching

COPQ (+cost/benefit) counting and reporting implemented to drive six sigma project selection

Rigorous review process implemented

1st GB training organized => 20 GB trained people

Awareness of people have been raised – basic understanding

3-YEAR (end of 2005) - Institutionalizing

Company level: Experience from over 100 projects

Complete processes, technologies, design and verify new processes, SCM, lean, factory level projects, translating results

Create and disseminate best practices throughout EIMO

Six Sigma targets are aligned with company goals and CTQ’s

Some experience with Six Sigma at supplier/customer

Six Sigma Cook Book created

Individual level: 20 GB’s with more than 10 projects experience, 10-20 GB some with 5 project experience, some in the beginning, 3-5 BB’s with more than 10 project experience

Reporting COPQ, improvement results etc. part of daily life

Capability to train all Six Sigma tools and resources internally

Six Sigma awareness training part of new people introduction, all people have basic understanding

Systematic career development for Six Sigma people

Six Sigma has been institutionalized and has gained wide acceptance as key improvement methodology

Benefit/cost ratio >4

5-YEAR (end of 2007) – Excellence in Six Sigma

Company level: Experience from over 200 projects, 6S widely applied throughout company

Capability to execute Six Sigma improvement widely in all processes (business and manufacturing)

Benchmarking and disseminating best practices widely in use

Metrics and reporting systems extensively used and understood throughout company

SIX SIGMA VISION


Copq cost benefit counting tracking system

Proposal for Master thesis subject Helmond, 1 Pécs)

Define what and how (principles) will be counted for e.g.

Internal COPQ (Scrap, rework, inspection, downtime, delivery inaccuracy, capcity loss…)

External COPQ (Reclamations, …)

How COPQ will be reported

By products

By processes

By teams

By technologies

Daily, weekly, monthly…

Where this information can be mined

Define who should be interested in COPQ

What system is used in reporting =>Power Play

Procedures how COPQ information drives Six Sigma project selection

We wiil be able to choose BB-projects that have biggest impact

We will be able to choose smaller (more manageable) projects for GB’s

Procedures how to report impact of Six Sigma projects

We will be able track and report impact of 6S projects (cost/benefit info)

COPQ/COST/BENEFIT COUNTING/TRACKING SYSTEM


Next steps

GB training module 2 Helmond, 1 Pécs)

Champion awakening training, choosing champions

Project selection procedures (Antti, Niina, Marko)

Start COPQ counting/reporting project (MSc thesis??)

GB project definitions

Project review&progress control with Kim, Wille, Janna, Johanna and GB’s

Awareness training

Create visibility for Six Sigma =>News letter, awareness training, 6S afternoon

NEXT STEPS


Agenda for 6s council europe 3 4 2003

SIX SIGMA – WHO DO WHAT? Helmond, 1 Pécs)

SIX SIGMA

AT

CUSTOMER

SIX SIGMA

AT

SUPPLIER

Compli-

cated

process

Product

Simple

process

Techno-

logy

DFSS

BB

BB

BB

BB

BB

MBB

MBB

MBB

GB

DMAIC

GB

BB

GB

CAP

BB

MBB

MBB

LEAN

SIX

SIGMA

BB

BB

MBB

BB


6s resources
6S RESOURCES Helmond, 1 Pécs)


Six sigma europe organisation
SIX SIGMA EUROPE ORGANISATION Helmond, 1 Pécs)

Timo Seppä

Seppo Jaakkola

Petri Virtanen

Minna Alitalo

Marko Salli

6S COUNCIL EUROPE

MBB+CHAMPIONS

OPERATIONALIZING + 6S STRATEGY

LAHTI

HOLLOLA

TOOLING

LAITILA

HELMOND

PÉCS

S

U

P

P

O

R

T

M

B

B

+

C

Wille Viittanen

Kim Gustafsson

Janne Martin?

Katja Äärilä?

M.S./F.N/H.N?

BB

BB

BB

BB

BB

GB

GB

GB

GB

GB

GB


How to track progress

FEED BACK/REVIEW MECHANISM Helmond, 1 Pécs)

Regular 6S council meetings timetables agreed => 1/month

Suggested agenda for meetings

Progress against operationalizing plans, achievements and concerns

Status of 6S projects, achieved results

Visitor presenting his/her project

Recognition

New ideas for 6S projects

Input to future plans

Other, what?

MBB reviews BB and GB progress 1x/1-2 weeks

Agenda for meetings

BB+GB meeting 4x/year => for developing our Six Sigma approach and share experiences

MBB team meeting (Eimo, Fibox, Lego, Grundfos)

Reporting to Pete

GE Support/Mentoring

HOW TO TRACK PROGRESS


Agenda for 6s council europe 3 4 2003

HOW TO TRACK PROGRESS – STATUS OF ALL PROJECTS Helmond, 1 Pécs)

PROJECT CHARTER



Selecting training gb s

18 Green belts trained (5 Lahti, 5 Hollola, 2 Laitila, 2 Tooling, 2 Helmond, 2 Pécs)

Internal search =>how? =>Virpi

Requirements:

Selfmotivated, interest towards improvement/6S

Possibility to do GB projects also after training

Basis OK (English, computers, preferably knowledge of production and/or improvement, studies)

Diversified group of people (mold, injection, painting, assy…)

Short interview

Production managers to champion course

Management participation (at least opening and closing sessions)

SELECTING+TRAINING GB’s


Training plan

Choose 5 GB’s for Lahti and Hollola, 2 for Tooling, 2 for Laitila, 2 for Helmond, 2 for Pécs =>18 GB’s

Training:

selfstudy CD-ROM/digital training

2 x 2 days GB training at Lahti

Trainers:

Marcel Kranenburg/GE

Antti Kontio MBB, Wille Viittanen+Kim Gustafsson BB

Time:

1st training week 11 (10.-14.3) in Lahti =>check winter holiday plans

2nd training week 14 (31.3-4.4)

3 weeks of project work between training

Projects must be selected for participants =>1st priority

1st 2 days is introduction to Six Sigma, DMAIC and 12-steps, some 6S Tools

2nd 2 days going into tools, DMAIC steps 1-3 must be completed before joining 2nd training

TRAINING PLAN


Where projects come from

Big strategic projects? =>6S COUNCIL Laitila, 2 for Helmond, 2 for Pécs =>18 GB’s

BB projects? Co-ordinated by Antti

GB projects? Co-ordinated by Antti

Development/R&D 6S projects? =>Niina

Pareto projects –they are working well in Hollola with Kim and Tomi =>continue with them

What to do when there is lack of BB’s or GB’s?

How to get initiatives? How to process initiatives? How to reward initiatives?

WHERE PROJECTS COME FROM