----- a french version is available upon request ----- This is a short - and I hope Zen ! -presentation (15 mn should be enough) aiming to make Executives, Board of directors, employees aware of what Lean Six Sigma is and the benefit they could have implementing it.

1. Athena
Consulting
A short introduction to Lean 6 Sigma
philosophy and methodology
Designed for Board members and Executives
for general knowledge purpose
D.LAPERE - December 2012

2. Several methods aiming to improve processes continuously
TPS
Toyota Problem
Solving
TQM Lean
Total Quality Manufacturing
Management Toyota
Continuous
Improvement
methods
Agile Six Sigma
Manufacturing Motorola, GE
…
Athena
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3. Why combining Six Sigma and Lean Manufacturing?
These are complementary methods and, moreover,
both are customer focused
Athena
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4. Sigma?
Firstly used in statistics … Statistics / probability:
How much deviation
from the average?
… Then transposed to industry
σ Sigma
Industry / Quality:
How far a given process
deviates from perfection?
But what is perfection ?
Athena
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5. 6 Sigma? As perfect as pratically possible
Defects per Million Opportunities
Logarithmic
Scale
6σ
1 000 000
308 537,0
100 000
66 807,0
6 Sigma
10 000
1 000
621,0
233,0
100
10
3,4
1
a
a
a
a
a
gm
gm
gm
gm
gm
Si
Si
Si
Si
Si
2
3
4
5
3.4 defects per 1.000.000 opportunities is considered as acceptable 6
and not far from perfection in real life that is to say a 99.9997% quality level
Athena
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6. Why 6σ and not 5 or 4σ? Example
4σ: Every hour the postal service would lose 20.000 pieces of mail
6σ: Every hour the postal service would lose 7 pieces of mail
Athena
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7. Why 6σ and not 4σ? Example
4σ  2 missed landing daily in main airports!
6σ  2 missed landing every 5 years
Athena
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8. Why 6σ and not 4σ? Example
4σ  Poisonous water during 15 min every day
6σ  1 min undrinkable water over several months
Athena
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9. Measure performance level of a process
 Problem solving approach
6σ
6 Sigma
 Data driven method
 Continuous improvement
Improve the process then
benchmark performance indicator
Athena
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10. DMAIC
Define processes to be improved and set up the related team and goals
Measure main key performance indicators
6σ Analyse defects and related reasons (Root-cause analysis)
Improve by tackling all the issues
Control, monitor and check that goals are achieved
Athena
Consulting
But what defines a process? -10-

11. What is a process?
A set of tasks aiming to a common goal
Procedures
Equipment
Material
Energy
People
Requirements Products
Ideas &
Work activities
Time Services
 Composed of tasks linked together
 Triggered by an event
 Possibly impacted by external factors
 Involving actors contributing to these tasks
 Providing a result meeting a customer expectations
Athena
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12. Outcome only matters
X Process
Y
Outcome
Department performance
Y = f(X)
Department performance
Department performance
Department performance
Department performance
Customer
Process performance
Process performance
What matters for the customer is not departments performance but the overall
process performance!
Athena
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13. 6σ phases (DMAIC)
Define the project goals, appoint the
Define team and agree on customer (internal
and external) deliverables
Measure and check the current process
Measure
performances to determine the baseline
Analyze defects, through a root-cause
Analyze
analysis, in order to determine the very
reasons of these defects
Athena
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14. 6σ phases (DMAIC)
Improve Improve the process by eliminating defects
Control Control future process performance
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15. Some of 6σ keywords
 Tools and methods
 Project management
 Business Process Mapping
 Design of Experiment
 Logical flow chart
 Chain of value
 XY Matrix
 Failure mode effect analysis
 Players
 Executive leadership
 Champions
 Master Black Belts
 Black Belts
 Green Belts
 Yellow Belts
Athena
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16. Lean management
Athena
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17. Identify flow of value
and
eliminate waste
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18. Figure out the flow of value-added activities,
i.e. activities a customer would be willing to pay for
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19. Find out valueless activities,
i.e. those that does not add any value in the eyes of the
customer
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20. 7 types of waste to be eliminated can be identified (7W’s):
Motion
People
Waiting time
Overproduction
Process
Processing time
Defects
Product
Inspection
Transportation
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21. Lean focuses on flow
flows and intends to stretch the flow towards
Lean focuses on
the customer in order to make it as lean, smooth
and seamless as possible
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22. Lean + 6σ
A combination of both Lean
and Six Sigma aiming to:
Improve
quality
Eliminate
waste
Reduce lead
time
Reduce total
cost
Athena
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23. Lean Six Sigma
Lean speeds up fulfilment by eliminating waste sources, and
thus, improves efficiency
Six Sigma focuses on deviations management, solving defects
and, as a result, reduces costs and enhances quality
Profitability, quality, competitive advantage
Athena
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24. Athena
Consulting
Thanks for your attention