OSDGB1

1. Lean Six Sigma
Department of Defense
Lean Six Sigma
-Introduction-
UNCLASSIFIED

2. Learning Objectives
Lean Six Sigma
 Class Introductions
 Review Training Materials and Software
 Establish Code of Conduct, Instructor
Expectations, and Logistics
 Understand the Adult Learning Environment
 Use data to establish a Lean Six Sigma baseline
for the class
 Review the Lean Six Sigma improvement process
and topics to be covered in class
2 UNCLASSIFIED

3. Class Introductions
Lean Six Sigma
 Name
 Organization and location
 Years experience with DoD
 Hobby/interest
 Project problem statement
 Expectations
3 UNCLASSIFIED

4. Training Materials and Software
Lean Six Sigma
 DEPMS: DoD Enterprise  MINITAB:
Performance Management System  Data Analysis
 Document Projects  Requires License
 Research Replicates
 www.minitab.com
 Gate Approvals
 DMAIC Templates  EXCEL:
 Other tools  Data Analysis
https://psxl.psteering.com/DEPMS  Requires Data Analysis add-in
 Choose Office-> EXCEL options; Select
Class Materials: Add-ins; Select Analysis ToolPak; click Go.
Select Analysis ToolPak, click OK.
 Laptop with MINITAB & EXCEL
 Access to DEPMS
 Simulation:
 Print-out of Class Slides  Role Instructions
 Web-link to:  Supply Store
 Student Participant Guide  Document Repository
 Minitab and EXCEL PEs
 DEPMS training (Prework)
 Glossary
4 UNCLASSIFIED

5. Code of Conduct
Lean Six Sigma
 Everyone participates with equal voice
 High level of participation needed for success
 Single discussions (respect the speaker)
 All ideas welcome
 Confidentiality - what happens here stays here!
 Respect our time together
 Return from breaks/lunch on time
 Use “parking lot” and “ELMO” to manage discussions
 Handle outside business on breaks
 Blackberries / Phones / electronics off or on vibrate
 Function as a team – everyone facilitates at least one
exercise
 Have fun!
5 UNCLASSIFIED

6. Instructor Expectations
Lean Six Sigma
 Instructors’ expectations are that you will:
 Come to class prepared
 Adhere to the Code of Conduct
 Ask questions and participate
 Practice team leadership and facilitation skills during class
 Teach-backs
 Simulation
 Class Exercises
 Keep an open mind
 Have fun!
6 UNCLASSIFIED

7. Classroom Logistics
Lean Six Sigma
 Class Hours
 Safety
 Fire exits and where to congregate
 Trips and other hazards
 Restroom facilities
 Breaks
 Lunch accommodations
 Others?
7 UNCLASSIFIED

8. Our Learning Environment
Lean Six Sigma
 Prework
 Classroom concept lecture / discussion
 Classroom application – Instructor led
 Classroom application – Team lead
 Classroom team teach-back
 Homework assignments
 Homework debrief
8 UNCLASSIFIED

9. How Do We Learn?
Lean Six Sigma
Retention Rate Teaching Techniques Characteristics
Time Pressured
5% Presentation
Content Focused
Spray and Pray
10% Reading
20% Audio-Visual
30% Demonstration
50% Discussion
75% Practice with Feedback Learner Focused
Interactive
80% Teach Others/Immediate Use Time-Consuming
9 UNCLASSIFIED

10. Class Baseline
Lean Six Sigma
 Statistical Baseline - Our personal knowledge:
 1 – I have never used statistical methods
 3 – I use some data occasionally
 5 – I use data frequently
 7 – I almost always use data and know what to do with it
 9 – I should be teaching this stuff
 Lean Baseline – Our personal knowledge:
 1 – I have never used lean tools/techniques
 3 – I use lean tools sometimes
 5 – I use lean tools a lot
 7 – I always use lean, regardless of the process/environment
 9 – I should be teaching this stuff
10 UNCLASSIFIED

11. Course Schedule
Lean Six Sigma
Monday Tuesday Wednesday Thursday Friday
25 Nov
1 – Introduction Teachbacks Teachbacks Teachbacks Review
6 – Measure 6 – Measure 9 - Round 2 13 – OSD Final
2 –Performance
Phase 3 Dec
Simulation Exam
Improvement 1 Dec
Overview 10 – Improve
7– Analyze
Phase Cont 14 - Project
Phase
3 – Management 10 Dec Presentations
Team
17 Dec
Change 8– Improve 11– Control
Project Phase Phase *Saturday
8 Dec 15 – DA Exam
4 – Define Phase 12 – Class
Prep
Review 18 Dec
5 – Round 1
Simulation 16 – DA Final
15 Dec
Exam
28 Nov
* Optional: Required for the award of the ARMY LSS ASI 11 UNCLASSIFIED

12. What We Have Covered
Lean Six Sigma
 Introduction to class instructors and participants
 Necessary software and training materials
 Code of Conduct, Instructor Expectations, and Class
Logistics
 An understanding of the learning process, learning
environment, and LSS learning focus
 Appreciation of our baseline familiarity and comfort level
working with statistical data and Lean
 Overview of the Lean Six Sigma Course Schedule
12 UNCLASSIFIED

13. Lean Six Sigma
Department of Defense
Lean Six Sigma
-Overview-
UNCLASSIFIED

14. Learning Objectives
Lean Six Sigma
 At the end of this training you will:
 Be aware of DoD policy regarding Lean Six Sigma deployment
 Be aware that Performance Improvement efforts should link to
enterprise value streams, linking mission and vision
 Appreciate that different deployment models that exist
 Appreciate differences between various project implementation
strategies and when to use each model
 Be aware of the history of Lean, Six Sigma and Theory of
Constraints
 Be aware of OSD’s LSS certification requirements
14 UNCLASSIFIED

15. Foundation to Lean 6 Sigma
Lean Six Sigma
Definitions of Insanity:
Doing the same thing over and over
and expecting a different outcome!
AND
Using the same logic to get out of the
trouble that got you there in the first
place!
-Albert Einstein
15 UNCLASSIFIED

16. Policy Overview
Lean Six Sigma
 Process Improvement Guidelines
 Principles and Tools
 OSD Performance Improvement / LSS Charter
 DepSecDef memo of 11 May 2006
 DepSecDef memo of 30 April 2007
 DoDD 5010.42 15 May 2008
 DoDI 5010.43 17 Jul 2009
 Performance Excellence… A Lean Six Sigma World-
Class Methodology
 Where to Start…Voice of the Customer
16 UNCLASSIFIED

17. Performance Improvement Cycle
Lean Six Sigma
PLANNING
1. Develop Vision,
Mission & Strategy
• Who am I?
• Where am I going?
• What do I need to get
done?
B.
Implement
Operational Plan 2. Conduct a Value
RE-ENTRY (Meet my
Stream Analysis
commitment)
• How will I get there?
A. C.
Create & Refine Monitor Progress
Operational Plan IMPLEMENTATION (How am I
(What’s my doing?)
plan?)
D.
Focus D. PIPI
on (How
Focus on CPI
can I do it again?
(How can can I it again?
How I do do it
How can I do it better?
4. Align & better? How can I
How can I kill it?) 3. Develop
kill it?
Deploy Goals Structure & Behavior
• How will I get • What will I need?
people to do it?
17 UNCLASSIFIED

18. Strategic Alignment
Lean Six Sigma
 The Define Tollgate requires a linkage to how this
project aligns to the organizational strategy.
 Include an organizational metric/metrics for which your
project will help improve
 Refer to your organization’s Strategic Plan and/or other
referenced documents
Required Define
Phase Deliverable
18 UNCLASSIFIED

19. Value Streams & DoD Enterprise
Lean Six Sigma
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Real Property & Installation Lifecycle Management
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Financial Management
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Value Streams
(red and yellow)
19 UNCLASSIFIED

20. DMAIC Model
Lean Six Sigma
20 UNCLASSIFIED

21. DMAIC Linkages
Lean Six Sigma
Gage R&R
Critical
Suppliers Inputs Process Outputs Customers Customer
Requirements
CTQ
Input, Process
& Output Defects
Fishbone - Potential X’s & Modes
Indicators
Process People Measurement
Operational
Step 3 Step 4
Definitions and Data X4 X2
Indicators Rework
No Y X3
X5 X1
Yes
Step 1 Step 2 Step 5 Step 6 Step 7 Environment Equipment Materials
ProcessCapabilityofLength
UCL
XY MATRIX
OCC
Improved Process
SEV
RP
ET
Proces
N
D
Process Data
LSL USL
Within
Potential Potential Potential Current
LSL 599 Overall
s Step Failure Failure Causes Controls
Control &
Target *
X-bar USL 601
Sample Mean 600.072
Potential (Within) Capability
Cp 0.28
Modes Effects
Sample N
StDev(W
100
ithin) 1.17308
StDev(Overall) 1.33501
CPL 0.30
CPU 0.26
Cpk 0.26
Step 1 M1 Y X1
LCL Overall Capability
Pp 0.25
PPL 0.27
PPU 0.23
Ppk 0.23
Step 2 M2 Y X2 Performance
Process Baseline
Cpm *
Pareto Step 3 M3 Y X3
FMEA
597 598 599 600 601 602 603
ObservedPerformance
PPM <LSL 280000.00
Exp. WithinPerform
PPM <LSL 180401.78
ance Exp. Overall Perform
PPM<LSL 210989.32
ance
Step 4 M4 Y X4
Stratification
PPM >USL 350000.00 PPM >USL 214448.35 PPM>USL 243487.40
PPM Total 630000.00 PPM Total 394850.13 PPMTotal 454476.72
Step 5 M5 Y X5
Baseline
Capability 1
21 UNCLASSIFIED