Lean Six Sigma White Belt Training

View the interactive version of this White Belt Training at: http://wb.goleansixsigma.com

White Belt: Learning Objectives

• After completing this Training, you will be able to:

• List the basic concepts and principles that underlie Lean Six Sigma improvement methods

• Describe the history of Lean and Six Sigma

• Distinguish between Lean and Six Sigma

• List the benefits of using Lean Six Sigma

• Define the Roles involved in Lean Six Sigma

• Recognize the 8 Wastes of processes

White Belt Modules

There are 4 modules in this course:

Introduction To Lean Six Sigma Roles The 8 Wastes DMAIC

Overview

What Is Lean Six Sigma?

Lean Six Sigma is a combination of two powerful methods:

Lean and Six Sigma.

• A Lean Process:

• Is faster

• Is more efficient and economical

• Delivers satisfactory quality

What Is A Lean Process?

What Is A Six Sigma Process?

A Six Sigma process has a 99.99966% defect-free rate.

This is equivalent to 3.4 DPMO (defects per million opportunities), or a single defect for every 294,000 units. How small does this look? The chart illustrates 1 defect in 294,000 units with powers of magnifications:

Where Did Lean Six Sigma Come From?

• Developed in the 1940s at Toyota • Taiichi Ohno: EVP Production Engineer • Toyota Production System (TPS) • TPS known as Lean in the USA

• Developed in the early 80s at Motorola • Bill Smith: Engineer • 1988: Malcolm Baldridge Quality Award • 1990: Mikel Harry starts Six Sigma Academy

Why Do Organizations Use Lean Six Sigma?

1. Lean Six Sigma Benefit: Increase Revenue

2. Lean Six Sigma Benefit: Decrease Costs

3. Lean Six Sigma Benefit: Increase Efficiency

4. Lean Six Sigma Benefit: Effective People

• Belt levels came from Karate

• Different belts indicate different levels of expertise

Lean Six Sigma Belt Levels

• Has overall understanding of Lean Six Sigma concepts

• Able to report process issues to Yellow Belts, Green Belts, Black Belts

• Able to use basic Lean Six Sigma vocabulary terms

White Belts

• Has a basic understanding of Lean Six Sigma concepts

• Receives additional just-in-time Lean Six Sigma training from Green Belts and Black Belts for projects

Yellow Belts

• Work as managers, process owners, technical experts, or in administrative functions

• Responsible for initiating and managing Lean Six Sigma Projects within their primary function

• Work closely with Black Belts and are trained in many of the same ways as Black Belts, but in less detail

Green Belts

• Trained in advanced Lean Six Sigma tools and methodology

• Hold full-time positions in Lean Six Sigma organizations

• Train, lead, and support Lean Six Sigma Teams, Green Belts, and Yellow Belts

• Function in multiple roles for Lean Six Sigma project teams: coach, mentor, teacher, leader, content expert

Black Belts

• Supported by Black Belts

• Usually a full-time position

• Work with executive management to select projects, align with company strategy, assist removal of barriers, and identify gaps

• Function in multiple roles for Lean Six Sigma implementation: coach, mentor, teacher, project leader, and content expert

Master Black Belts

• Have a general understanding of Lean Six Sigma

• Help select, support, and promote projects to completion

• Provide resources for project teams and removes barriers beyond team’s control

• Essential to smoothing the way to a culture of process improvement

Champions

What Is Waste?

• Waste is:

• “muda” in Japanese

• a strain on an organization’s time and resources

• doesn’t add value for the customer

• The more you can reduce Waste, the better

Seeing With New Eyes

“The real voyage of discovery consists not in seeking new lands but seeing with new eyes.” - Marcel Proust

Learning To See With New Eyes

• Process improvement requires us to look at our processes in a new way

• Organizations that use Lean Six Sigma have different conversations

• Is it OK to challenge the status quo

• Asking “Why” is not reacted to defensively

• An example of this new view of work is The 8 Wastes tool

The 8 Wastes

Here is a chart of the 8 Wastes:

• A trick to memorize them is the acronym, “DOWNTIME.”

The 8 WastesDOWNTIME is an acronym for the 8 Wastes

Once Waste Is Identified

• What do you do?

• How can you:

• Eliminate?

• Simplify?

• Streamline?

• Minimize?

Why DMAIC?• DMAIC is a methodology for root cause analysis

• DMAIC should be used when:

• there is a problem and the root cause is unknown

• the stakes are high and we need to be absolutely sure the solution fixes the problem

• a problem exists, solutions have been tried, but the root cause is still unknown

• DMAIC should not be used when there are some problems where the root cause and solution are already known

• DMAIC is the Six Sigma methodology to conduct root cause analysis

• Define the problem, process, and customer(s) of the process

• Measure baseline measurements to characterize the problem or current state

• Analyze the process; Collect and analyze casual data to determine the root causes of Defects

• Improve solutions to remove/reduce sources of the problem. Confirm improvement w/ data

• Control by maintaining the gains with documentation and monitoring the improved process

DMAIC Methodology

DMAIC Roadmap

Here is a high level roadmap of DMAIC:

Define Measure Analyze Improve Control

Start Improving Today.View the interactive version of this White Belt Training at:

http://wb.goleansixsigma.com

Register For Your Lean Six Sigma White Belt Certification