Operational Excelence: better, faster, cheaper
3 roles: customer, processor, supplier
Voice of customer VOC » Critical to quality CTQ » Metrics
Performance attributes is categorized to three (kano model): dissatisfier, satisfier, and delighter.
Variation; controlling variation within specification limit is key. Mean, variance, stdev, LCL, UCL.
Quality at the source: (1) Quality by design (2) Quality by process monitoring & control (3) Quality by self check and verification
Pokayoke: prevention, facilitation, detection
Lean principles: principle to maximize customer value by minimizing waste. 8 waste: TIMWOODS, Travel, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, Skill underutilized
Process Mapping: detail, swimlane, value stream map
FMEA: Design FMEA, Process FMEA
Control plan
Key Roles in op excellence; project champion; 1. Design for six sigma 2. Six sigma and lean 3. Process monitoring
Alignment of kpi. 1) Reduce KPI 2) Vertical line sight 3) Horizontal line sight
Choose right methodology: 1) Process Management 2) Project 3) Lean Project 4) Six Sigma DMAIC 5) Six sigma for design DMADV 6)SIPOC
Process/value stream management: 1)Stdzd work 2) Control plan 3)Process metric & KPI
Lean Event or Kaizen Event or Workout to get improvement from first hand executor/operator. It is guided by kaizen facilitator
Six Sigma DMAIC for problem with unknown cause: Define, Measure, Analyze, Improve, Control
DFSS, Design for Six Sigma used for design/redesign product/process/service. Steps: DMADV, Define, Measure, Analyze, Design, Verify
Challanges for implementation op excellence: fear of job cut, resistance to changes, back to old habit, too many project,
Audit for sustainable implementation