The second gives an overview of the sbr programme, outlining the sbrs high level project approach to achieving and sustaining business benefits through the application of lean six sigma concepts. A brief introduction to lean, six sigma and lean six sigma if you are starting to learn about the concepts of streamlining a business process, you are at the right place. Engage all employees to use effective problem solving tools to make permanent and. Asq six sigma black belt total productive maintenance questions. The lean maintenance six sigma black belt article explores why are there so few six sigma black belts in industrial maintenance. Tpm is implemented as part of the improve phase in a dmaic six sigma project. High levels of performance mean high volume, fast turnaround times, very few errors or defects and low cost. For more information about six sigma, please visit the links. In the manufacturing future, there will be less humans and more automation. Effective maintenance should also involve all areas of the organisation. Lean maintenance for lean manufacturing using six sigma dmaic before putting new and 30 or 40 year old machines together into lean manufacturing lines, do you know how to get the near 100% uptime. Lean six sigma service best for maintenance services.
The combination of leans concepts and principles with six sigmas dmaic framework to bring. Lean accelerates six sigma, delivering greater results than what would typically be achieved by lean or six sigma individually. It was recommended to introduce lean sixsigma for process optimization system to accomplish the aim of continuous improvement for. Operator and maintainer training upskill maintenance to be trainers and equipment improvers upskill operators to be equipment maintainers autonomous. This six sigma black belt certification course is the final stage of the. As we can see in table 2, both lean and six sigma uncover similar issues. Lean six sigma lack of customer focus lack of customer focus lack of staff empowerment inadequate measurement systems untidy, inefficient work spaces suboptimal processes suboptimal maintenance practices defect opportunities lack of crosstraining outdated processes and.
Lean six sigma is a method of improving the quality and profitability based on. Case 1 will illustrate the application of lean six sigma in. Nov 01, 2003 suggestions for using this methodology to improve department practices. Application of lean sixsigma methodology to reduce the. By robson quinello since years 80, the six sigma methodology comes gaining notoriety in some. In the manufacturing future, there will be less humans and more automation, thus more focus on lean maintenance. You must first understand the three categories of downtime. In particular the emphasis is on obtaining the benefits of both methodologies, whilst minimizing any potential weaknesses. Lean six sigma has been applied successfully to virtually any industry.
This presentation will discuss lean six sigma theory, basic principles of the methodology and case studies showing the use of tools. Browse the full collection of free resources on lean six sigma and process improvement, including tutorials, webcasts, and white papers. If you want a process that is fast, defect free, and without waste, then you need lss. Apr 12, 2017 this presentation will discuss lean six sigma theory, basic principles of the methodology and case studies showing the use of tools. The benefits are there for the taking the benefits always include increased market share, lowered cost higher profits and happier customers and shareholders lean is the. Six sigma templates and calculators to assist a six sigma or lean project manager. Learn how to apply the lean six sigma toolbox to each process in our specialized workshops or become a certified specialized professional or team. The efficiency of the maintenance of the industrial systems is a major economic. Lean maintenance for lean manufacturing plant maintenance. Lean and six sigma concepts application in pharmaceutical industry article pdf available in international journal for quality research 52 june 2011 with 7,499 reads how we measure reads. Contribution to the optimization of strategy of maintenance by lean six sigma article pdf available in physics procedia 55. Total productive maintenance tpm tutorial lean six sigma.
Lean six sigma tpm synergy when using lean maintenance, six sigma, and tpm together, we should probe an opportunity with a little different set of questions and assumptions traditionally, we might ask. In the pulp and paper industry, maintenance is a service to the operating. Leading a lean six sigma project will often provide an opportunity for exposure to other functions and senior management. The projectthe goal of the lean six sigma project was to initiate improvements to army watercraft maintenance processes to. Lean six sigma for service viii bill kastle, mark price, kevin simoninfor proving that lean six sigma works by leading some of the largest, most ambitious and most successful lean and six sigma deployments ever undertaken. Six sigma concept in the maintenance process of technical systems 97 pare the processes, which, in its turn, enables making a decision on arrangement of resources for better performances. Maintenance work order backlog and the six sigma process abstract. To get from the bottom to the top it is easier to use evenly spaced comfortably sized steps. An effective maintenance system will support autonomous maintenance. Contribution to the optimization of strategy of maintenance. Address root causes that reduce the capacity of equipment. Most maintenance personnel are taught on the job or learn their own techniques during the course of several years. Pdf development of world class manufacturing framework. A lean six sigma project to improve watercraft maintenance.
Lean six sigma is widely used in production, but it is just now breaking the surface in maintenance functions. Development of world class manufacturing framework by using six sigma, total productive maintenance and lean. More jobs also are beginning to appear in the aviation industry that require lean or six sigma training. Application of the six sigma method for improving maintenance. Maintenance and six sigma basic suggestions for six sigma use in the maintenance. We will introduce you to the methodologies of lean. Preventive maintenance principles mit opencourseware. Lean six sigma lss aims to drive business process improvements through adopting the key features of both lean and six sigma and combining these features in to a single approach towards business. Six sigma is six sigma is shorthand for a discipline that allows any business to design, improve and manage its processes so that they perform at their highest possible levels. The second gives an overview of the sbr programme, outlining the sbrs high level project approach to. A brief introduction to lean, six sigma and lean six sigma. Lean six sigma lack of customer focus lack of customer focus lack of staff empowerment inadequate measurement. Six sigma improves fleet operations government fleet. The six sigma memory jogger ii p 144 if comparing a group to a specific value use a 1sample ttest the lean.
Tpm methodology implementation, change of behaviour and culture. The complete guide to lean project management smartsheet. Connect with a lean six sigma expert for a free initial consultation to learn more about how lean six sigma can be easily applied within your organization. You must maintain each step as you progress, or the whole thing will crumble how does autonomous maintenance work. The combination of leans concepts and principles with six sigmas dmaic framework to bring about process improvements is the essence of lss mohsen f. Case 1 will illustrate the application of lean six sigma in scheduled preventive maintenance for slurry pumps operating in the oil sands industry. This video will help you better understand the six sigma methodology by applying the dmaic framework cycle within a business model. Combining these two methods gives your improvement team a comprehensive tool set to increase the speed and effectiveness of any process within your organization resulting. Maintenance work order backlog and the sixsigma process. Lean six sigma is widely used in production, but it is just getting started in maintenance. Using lean six sigma measurement tools in maintenance. Which of the following is the best way to enhance the longterm availability of a machine. Such as an mtbf calculator, dpmo calculator, fmea template, sipoc template, rty calculator, dmaic contract, oee calcu read more. Mar 12, 2018 a brief introduction to lean, six sigma and lean six sigma if you are starting to learn about the concepts of streamlining a business process, you are at the right place.
Learn how to apply the lean six sigma toolbox to each process in our specialized workshops or become a certified specialized. For more information about six sigma, please visit. However, as many another tool of quality or methodology, for us from maintenance area, will be necessary some adaptations to reach sucessfully our goals. Total productive maintenance tpm six sigma study guide. The way that the stages of autonomous maintenance are described as steps, promotes how autonomous maintenance works. In this prerecorded, live training seminar shot at the peterbilt manufacturing training center in denton, tx, mike wroblewski, a senior lean consultant from gemba consulting and the kaizen institute explains why total productive maintenance tpm is not optional for lean thinking companies who rely on machines and equipment to satisfy customer demand. Effectively and efficiently employ machinery, materials, methods and manpower through the use of lean six sigma tools.
A program requires participation from all levels of an organization. The implementation of a lean six sigma framework to. We will introduce you to the methodologies of lean, six sigma and lean six sigma. S ince the 1980s, six sigma methodology has been applied in a growing number of companies. Six sigma in maintenance free download as pdf file.
Tools created for six sigma project managers to accelerate execution. Lean six sigma and establishes some common themes, then presents sbrs lean six sigma model. Now that we understand the principles of lean thinking, we can look at how three of the main lean methodologiesthe deming cycle, six sigma, and kanbanapproach project management. Jan 19, 2004 you might call this kaizen for maintenance reliability, or jumping from four sigma to six. Suggestions for using this methodology to improve department practices. Here is how to implement a measurement system using data to identify. The lean six sigma black belt training is the most exclusive certification for the lean six sigma quality management methodology. Here is how to implement a measurement system using data to identify root causes, prioritize workloads and drive improvements in a maintenance operation. Summer 2004 i erik smith, lfm 03 intel corporation esd. Maintenance work order backlog and the sixsigma process abstract. Lean six sigma then is a methodology that looks to combine the best of both the lean manufacturing and the 6 sigma approaches. The benefits are there for the taking the benefits always include increased market share, lowered cost higher profits and happier customers and shareholders lean is the only answer known that provides these benefits lean never fails if you really do it saying lean is not doing lean. Maintenance technicians are liberated from mundane, routine maintenance. Total productive maintenance tpm lean six sigma training.
Paper manufacturing is a very capital and laborintense process with an end product commodity sold in an elastic market. Mar 18, 2010 six sigma proves helpful in daily fleet operations. A new look at some aspects of maintenance and improvement of. Lean six sigma certification training online course. Objectives explain the differences between lean, six sigma 6. Lean six sigma is a method that relies on a collaborative team effort to improve performance by systematically removing waste and reducing variation.
Defects, overproduction, waiting, nonutilized talent, transportation, inventory, motion, and extraprocessing. Lean six sigma is implemented through projects and projects have leaders. This exposure is in the context of someone who can find and fix a problem. The main reason behind this fact is that in many companies the maintenance activities are conducted by comparatively lessskilled. Relate six sigma concepts to the overall business mission and. Toolbox learn about commonly used tools for measuring. How lean six sigma applies to the aviation industry six. Pacific reach 2017 served as a pilot program capping the twoyear project. Jun 23, 2017 now that we understand the principles of lean thinking, we can look at how three of the main lean methodologiesthe deming cycle, six sigma, and kanbanapproach project management. Think about your organization as a collection of processes, with inputs that determine the output. Lean maintenance using six sigma dmaic quality digest.
Contribution to the optimization of strategy of maintenance by lean. However, as with any tool of quality or methodology, it must be adapted by a maintenance department to successfully reach its individual goals. They all follow a disciplined approach to project management, stress optimization of the value stream, and map the value stream in its current state. It is not easy to implement the lean six sigma service in several companies. I, also, appreciate the comments of my 6 sigma instructor, espelosin eduardo. Lets apply six sigmas define, measure, analyze, improve and control steps to the problem of equipment downtime and see how it can promote lean maintenance. It combines lean manufacturing lean enterprise and six sigma to eliminate the eight kinds of waste. Lean six sigma methodologies and tools are now applied to any process. The goal of predictive maintenance is to reduce unplanned downtime but there are more direct benefits that are further down the road once a program is in place and proven over. Driving change in maintenance operations is a difficult task. In this prerecorded, live training seminar shot at the peterbilt manufacturing training center in denton, tx, mike wroblewski, a senior lean consultant from gemba.
Lss has the ability to maximize shareholder value by achieving an extremely fast rate of improvement in he following areas. By robson quinello since years 80, the six sigma methodology comes gaining notoriety in some companies. As the ultimate goal of six sigma concept is work in the process with no errors, it is also necessary to trace the errors which occur in the process. Continuously improving manufacturing tpm, lean and six. Total productive maintenance tpm summary of tpm tpm was developed in the 1970s as a method of involving machine operators in the preventive maintenance of their machines a reaction to increasing specialization and centralization of the maintenance function that had created divisionoflabor barriers between operators and the maintenance of.
Basic lean six sigma lss lean and six sigma methodologies focuses and fixes different areas of a process. Lean six sigma gives leaders in aviation the tools and techniques they need to fix flaws in their. Engage all employees to use effective problem solving tools to make permanent and significant reduction in plant losses. Nov 01, 2017 this video will help you better understand the six sigma methodology by applying the dmaic framework cycle within a business model. By measuring to establish a baseline, you can then verify the process improvements. The main reason behind this fact is that in many companies the maintenance activities are conducted by comparatively lessskilled professionals who do may not have the capability to recognize the complexities of lean methodologies and concepts. Pdf contribution to the optimization of strategy of.
215 66 52 225 1137 1452 952 1270 181 149 1014 244 1173 79 763 1636 52 1446 274 908 1300 218 1549 1109 32 359 1336 1084 984 4 179 367 251 1171 1063 196 362 496 478 598