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- Herausgeber: Van Haren Publishing
- Kategorie: Fachliteratur
- Sprache: Englisch
This book is intended for those who want to get started with carrying out improvement projects on the shop floor or in their own work environment. In addition, this book is intended for anyone who participates as a team member in a larger Lean or Six Sigma, Green or Black Belt project. In terms of structure, this book follows the LSSA syllabus for Lean Six Sigma Yellow Belt. All techniques mentioned in this syllabus are covered in this book. It is advised to also use the accompanying exercise book.
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Veröffentlichungsjahr: 2021
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Title:
Lean Six Sigma Yellow & Orange Belt60 Exercises and Rationals
Series:
Climbing the Mountain
Author:
ir. H.C. Theisens
Publisher:
Van Haren Publishing, ’s-Hertogenbosch, www.vanharen.net
Edition:
Second revised edition, 2021ISBN 9789492240361 / 9789401809795NUR 100
Copyright:
© Van Haren Publishing
All rights reserved. No part of this book may be reproduced in any form or by any means, electronic, photocopying or otherwise, without the prior written permission of the publisher.
Portions of information contained in this book are printed with permission of Minitab Inc. All rights reserved. MINITAB® and all other trademarks and logos for the company’s products and services are the exclusive property of Minitab Inc. All other marks referenced remain the property of their respective owners. See minitab.com for more information.
The structure of this book is based on the LSSA® Skill set (rev 3.2, 2021) and the Continuous Improvement Maturity Model – CIMM™. You have the permission to share and distribute this model in its original form by referencing the publisher and author, (LSSA®, Theisens et. al., 2021).
Printed in the Netherlands.
Content
HOW TO USE THIS BOOK
1 WORLD CLASS
1.1 CONTINUOUS IMPROVEMENT
1.1.1 History of Lean and Six Sigma
1.1.2 Lean principles
1.1.3 House of Quality
1.1.4 Eight types of Waste
1.1.5 CIMM–framework
1.2 CUSTOMER VALUE (VOC & CTQ)
1.2.1 CTQ – Nursing home
1.2.2 CTQ – Implementation organization
1.2.3 CTQ – Ball bearing on shaft
1.2.4 CTQ–Flowdown – Baking pancakes
1.2.5 CTQ–Flowdown – Hotel room
2 POLICY DEVELOPMENT AND DEPLOYMENT
2.1 POLICY DEVELOPMENT
2.1.1 Mission, vision and core values
2.1.2 Competitive strategies
2.1.3 Cost of Poor Quality
2.2 POLICY DEPLOYMENT
2.2.1 Change management
3 PROJECT MANAGEMENT
3.1 MANAGING A PROJECT
3.1.1 Project prioritization (OB)
3.1.2 Project charter
3.2 PROCESS IMPROVEMENT ROADMAPS
3.2.1 PDCA–roadmap
3.2.2 DMAIC–roadmap
4 CIMM LEVEL I – CREATING A SOLID FOUNDATION
4.1 PROFESSIONAL WORK ENVIRONMENT
4.1.1 5S – At the office
4.1.2 5S – On a computer
4.1.3 5S – Activities
4.1.4 5S – Gemba walk
4.2 STANDARDIZED WORK
4.2.1 Standard Operating Procedure – Paper plane folding
4.2.2 One point lesson
4.3 QUALITY MANAGEMENT
4.3.1 Effective process control methods
5 CIMM LEVEL II – CREATING A CONTINUOUS IMPROVEMENT CULTURE
5.1 VISUAL MANAGEMENT
5.1.1 Visualization in the workplace
5.2 PERFORMANCE MANAGEMENT
5.2.1 Ohno Circle
5.2.2 Root cause analysis
5.3 BASIC QUALITY TOOLS
5.3.1 Affinity diagram – Students
5.3.2 5–Why technique – Problem solving
5.3.3 Ishikawa – Pizza complaints
5.3.4 Cause & Effect matrix – Baking pancakes
EXCEL
5.3.5 Scatter plot – Electronic system
5.3.6 Pareto chart – Customer satisfaction
5.3.7 Bar chart – Corona
5.3.8 Bar chart – Top
5.3.9 Bar chart – CPU2000
5.3.10 Pie chart – Flashlight production
5.3.11 Time series plot – COVID–cases
5.3.12 Time series plot – Meatballs
5.3.13 Histogram – Meatballs
5.3.14 Histogram - Welfare
5.3.15 Boxplot – Coffee pods (OB)
6 CIMM LEVEL III – CREATING STABLE & EFFICIENT PROCESSES
6.1 PROCESS MAPPING
6.1.1 SIPOC – Baking Pancakes
6.1.2 Flowchart – Flashlight production
6.2 PERFORMANCE METRICS
6.2.1 Takt time – Flashlight production
6.2.2 Takt time – Fines
6.2.3 Lead time – Letters
6.2.4 First Time Right (FTR) and Rolled Throughput Yield (RTY)
6.3 BASIC STATISTICS
6.3.1 Scale types (OB)
6.3.2 Mean and median
6.4 VALUE STREAM ANALYSIS
6.4.1 Three M’s and eight wastes
6.4.2 Waste identification – Logistical process
6.4.3 Process FMEA – Baking pancakes (OB)
6.4.4 Poka Yoke – Practical examples
7 CIMM LEVEL IV – CREATING CAPABLE PROCESSES
7.1 STATISTICS
7.1.1 Scale types
7.1.2 Mean and median
7.1.3 Variance, standard deviation and range (OB)
7.1.4 Probability theory – Tossing dice (OB)
7.1.5 Probability theory – Vase with marbles (OB)
7.1.6 Population versus sample (OB)
7.1.7 Measurement procedures and systems (OB)
RATIONALS
1 WORLD CLASS
1.1 CONTINUOUS IMPROVEMENT
1.1.1 History of Lean and Six Sigma
1.1.2 Lean principles
1.1.3 House of Quality
1.1.4 Eight types of Waste
1.1.5 CIMM–framework
1.2 CUSTOMER VALUE (VOC & CTQ)
1.2.1 CTQ – Nursing home
1.2.2 CTQ – Implementation organization
1.2.3 CTQ – Ball bearing on shaft
1.2.4 CTQ–Flowdown – Baking Pancakes
1.2.5 CTQ–Flowdown – Hotel room
2 POLICY DEVELOPMENT AND DEPLOYMENT
2.1 POLICY DEVELOPMENT
2.1.1 Mission, vision and core values
2.1.2 Value strategies
2.1.3 Cost of Poor Quality
2.2 POLICY DEPLOYMENT
2.2.1 Change management
3 PROJECT MANAGEMENT
3.1 MANAGING A PROJECT
3.1.1 Project prioritization
3.1.2 Project charter
3.1.3 Motivating and involving project members
3.1.4 Project delay
3.1.5 Project risks
3.2 PROCESS IMPROVEMENT ROADMAPS
3.2.1 PDCA–roadmap
3.2.2 DMAIC–roadmap
4 CIMM LEVEL I – CREATING A SOLID FOUNDATION
4.1 PROFESSIONAL WORK ENVIRONMENT
4.1.1 5S – At the office
4.1.2 5S – On a computer
4.1.3 5S – Activities
4.1.4 5S – Gemba walk
4.2 STANDARDIZED WORK
4.2.1 Standard Operating Procedure – Paper plane folding
4.2.2 One point lesson
4.3 QUALITY MANAGEMENT
4.3.1 Effective process control methods
5 CIMM LEVEL II – CREATING A CONTINUOUS IMPROVEMENT CULTURE
5.1 VISUAL MANAGEMENT
5.1.1 Visualization in the workplace
5.2 PERFORMANCE MANAGEMENT
5.2.1 Ohno Circle
5.2.2 Root cause analysis
5.3 BASIC QUALITY TOOLS
5.3.1 Affinity diagram – Students
5.3.2 5–Why technique – Problem solving
5.3.3 Ishikawa – Pizza complaints
5.3.4 Cause & Effect – Baking Pancakes
EXCEL
5.3.5 Scatter plot – Electronic system
5.3.6 Pareto chart – Customer satisfaction
5.3.7 Bar chart – Corona
5.3.8 Bar chart – Top
5.3.9 Bar chart – CPU2000
5.3.10 Pie chart – Flashlight production
5.3.11 Time series plot – COVID–cases
5.3.12 Time series plot – Meatballs
5.3.13 Histogram – Meatballs
5.3.14 Histogram – Welfare
5.3.15 Boxplot – Coffee pods (OB)
6 CIMM LEVEL III – CREATING STABLE & EFFICIENT PROCESSES
6.1 PROCESS MAPPING
6.1.1 SIPOC – Baking Pancakes
6.1.2 Flowchart – Flashlight production
6.2 PERFORMANCE METRICS
6.2.1 Takt time – Flashlight production
6.2.2 Takt time – Fines
6.2.3 Lead time – Letters
6.2.4 First Time Right (FTR) and Rolled Throughput Yield (RTY)
6.3 BASIC STATISTICS
6.3.1 Scale types (OB)
6.3.2 Mean and median
6.4 VALUE STREAM ANALYSIS
6.4.1 Three M’s and eight wastes
6.4.2 Waste identification – Logistical process
6.4.3 Process FMEA – Baking pancakes (OB)
6.4.4 Poka Yoke – Practical examples
7 CIMM LEVEL IV – CREATING CAPABLE PROCESSES
7.1 STATISTICS
7.1.1 Scale types
7.1.2 Mean and median
7.1.3 Variance, standard deviation and range (OB)
7.1.4 Probability theory – Tossing dice (OB)
7.1.5 Probability theory – Vase with marbles (OB)
7.1.6 Population versus sample (OB)
7.1.7 Measurement procedures and systems (OB)
How to use this book
Many excellent books have been written on Lean and Six Sigma. However, just reading the books will not give you the skills to use the techniques successfully. You can develop these skills by making exercises. This book contains 60 exercises and rationals and is therefore a valuable addition to any theoretical Lean and Six Sigma course. Even experienced Lean Six Sigma specialists can use this exercise book to improve their practical skills. Finally, this book is useful for trainers and teachers who provide training within their own organization or in education.
The structure of this exercise book is based on the "Continuous Improvement Maturity Model" (CIMM). CIMM is an open standard which is maintained by the Lean Six Sigma Academy (LSSA). This framework describes the process of continuous improvement from the initial phase to the delivery of products and services at the level of ‘World Class’. The CIMM framework connects the different methods and encompasses the most commonly applied techniques in the field of problem solving, continuous improvement and new product development.
This exercise book is a supplement to the textbook ‘Climbing the Mountain’ by H.C. Theisens. Together, these books form the basis for developing yourself in the beautiful field of problem solving and continuous improvement. This book contains examples from multiple sectors. However, all exercises can be made without having prior knowledge of a certain sector.
To make the exercises in this book, sometimes Excel is used. The data files required for the exercises can be downloaded from the website of the LSSA: www.lssa.eu.
If you only want to practice with Lean, it is sufficient to make the exercises in chapters 1 to 6 only. Six Sigma topics are covered in Chapter 7. The exercises that only need to be completed by Orange Belts are indicated by ‘(OB)’.
