AGENDA FOR 6S COUNCIL EUROPE 3.4.2003

Antti Kontio (22.01.2003)

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


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


6S OPERATIONALIZING PLAN EUROPE

TARGETS/EXPECTATIONS

6S+MBB

ASSESSMENT+REVIEW

FEEDBACK FROMGE/Marcel

Present state analysisBenchmarking

6S council+BBs

MEASUREMENT+TRACKING

REWARDEARLY SUCCESS

COACHING

SUPPORTINFRASTRUCTURE

RESOURCES

TRAINING

REPORTING

DEPLOYMENTINITIAL PLAN

IMPROVEDEPLOYMENT PLAN

SIX SIGMA VISION+NEED FOR 6S

PROJECTS

TARGETS/EXPECTATIONS

FOR BB+GB

COST OUTYIELD…

6S COUNCILCHAMPIONS ON BOARDMBB NETWORKGE SUPPORT2 BBs Kim + WilleChoosing 5 GB’s/Plant

GB TrainingAwareness trainingCAP for BBsDFSS/DMAIC

Project selectionAssign high leverageprojects for BBs+GBsEnsure early wins

MBB coaches + facilitatesBBs + GBs

Results reported to 6SC

Reward good results successestraining/project completion

REPORT TO 6SCOUNCIL+PVI

ASSESSMENTCRITERIA

Measure progress

NEXTPROJECTS

TRANSLATERESULTS

PA

C D

1st W

ave


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


GB PROJECTS


ONGOING BB PROJECTS

• Wille– 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)


OPERATING PLAN


CURRENT STATE ANALYSIS – INDIVIDUAL LEVEL

PLAYERS Number of players

1 st project 2nd project 5th project Experienced Guru

MBB 1 1

BB- done own projects

3 2 1

BB – Coached GB’s

0

GB 20 20

CHAMPIONS ?


DMAIC

DFSS

LEANSIX

SIGMA

Someexperi-ence

Six SixmaInstitu-

tionalized

CAP

No experi-ence

Experi-ence

Six SigmaExcel-lence

SIX SIGMA CAPABILITY CURRENT STATE ANALYSIS

NOW

1 YEAR

3 YEARS

5 YEARS


DMAIC

DFSS

IMD PaintingInjectionmolding

IMLPad

printing USW insertAssembly

SCMBezel

AssemblySPC

PROCESSES WHERE 6S HAVE BEEN APPLIED


COPQREPOR-

TING ANDSELECTIONCRITERIA

6S-TRACKER

SOFT-WARE

CTQ FLOWDOWN

FROMCOMPANY

GOALS

PROJECTSCHOSENBASED

ON FEELING OR EMERGENCY

PROJECTS CHOSEN BASED

ON FACTS

ImportantThere are projectsNumber of projects

ImportantImpact of project

ImportantCTQ alignment with company goals and external CTQ’s

Project scopeSingle product orpart of simple processProduction processes

Project scope• In addition: Complete processes, technologies, design andverify new processes, SCM, lean, factory level projects• Translating results• Create and disseminate best practices

Project scope• In addition: Mission critical projects• Projects derived directly from goals

SIX SIGMA ATSUPPLIER/CUSTOMER

INTERNAL FOCUS ALSO EXTERNALLY


SIX SIGMA VISION1-YEAR (2003) – Re-implementation of Six Sigma

– 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


COPQ/COST/BENEFIT COUNTING/TRACKING SYSTEM

• Proposal for Master thesis subject

• 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)


NEXT STEPS

• GB training module 2

• 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


DMAIC

DFSS

LEANSIX

SIGMA

Simpleprocess

Compli-cated

process

CAP

ProductTechno-

logy

SIX SIGMAAT

CUSTOMER

SIX SIGMAAT

SUPPLIER

x

BB

GB

MBB

GB GBBB

BB BBBB

BBMBB MBB

MBBMBB MBBBB BB

BB

SIX SIGMA – WHO DO WHAT?


6S RESOURCES

PLAYERS LAHTI HOLLOLA TOOLING LAITILA HELMOND PÈCS TOTAL

MBB 1 1

BB 1 1 2

GB 8 (=>9) 5 2 1 2 1 20

C ?


SIX SIGMA EUROPE ORGANISATION

6S COUNCIL EUROPE

MBB+CHAMPIONS

LAHTI HOLLOLA TOOLING HELMONDLAITILA PÉCS

BB BB BB BB

GB GB GB GB GBGB

MBB+C

OPERATIONALIZING + 6S STRATEGY

SUPPORT

BBJanne Martin? Katja Äärilä?

Timo SeppäSeppo JaakkolaPetri VirtanenMinna AlitaloMarko Salli

Kim GustafssonWille Viittanen M.S./F.N/H.N?


HOW TO TRACK PROGRESS

FEED BACK/REVIEW MECHANISM– 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 – STATUS OF ALL PROJECTS

PROJECT CHARTER


HOW TO TRACK PROGRESS – INDIVIDUAL PROJECTS


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)


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


WHERE PROJECTS COME FROM

• Big strategic projects? =>6S COUNCIL

• 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?

AGENDA FOR 6S COUNCIL EUROPE 3.4.2003

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Transcript of AGENDA FOR 6S COUNCIL EUROPE 3.4.2003