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Has Anyone Here Implemented Lean/Six Sigma?  
User currently offlineUTA_flyinghigh From Tunisia, joined Oct 2001, 6495 posts, RR: 50
Posted (6 years 12 months 1 day 15 hours ago) and read 3591 times:

As the title says, has anyone had the "pleasure" of implementing Lean, Six Sigma or both in their company ?
I would be very interested in learning how you did it and what was the outcome.

Thx,

UTA  

Edit : typos rhaaaaaaaaa

[Edited 2007-09-25 15:51:47]


Fly to live, live to fly - Air France/KLM Flying Blue Platinum, BMI Diamond Club Gold, Emirates Skywards
27 replies: All unread, showing first 25:
 
User currently offlineScrubbsYWG From Canada, joined Mar 2007, 1495 posts, RR: 0
Reply 1, posted (6 years 12 months 1 day 15 hours ago) and read 3569 times:

I worked for over a year in a process engineer position at a company that had a Lean program. It was already instituted by the time i got there, but most of my work was set on projects with the lean concept in mind. I took a 64 hour course in Lean, and i also wrote articles for a publication on what other companies' lean initiatives were in my province.

Lean is all about a culture change. I dont know what company you work for, but if you are just starting out on a lean journey, it will be a big step to convince the rank and file, as well as everybody else that this is not a way to find people to lay off. Lean is about eliminating waste, not employees. Some companies i have talked do talk about things like that, which as soon as you do it, you will lose people. Sometimes it is very hard for people to see both sides of the fence, and get very defensive when things like lean are brought up.

You must work very hard to get everyone involved in lean. Seminars, training, inclusion in continuous improvement teams where anyone can come up with ideas is important. Why shouldnt the employees that work on the floor everyday be the ones to find better ways to do their jobs?

Lean is also not an overnight thing. It will take years for things to make sense, and a bottom line advantage may not come quickly, that is where company leadership must be able to be in it for the long run. Companies like toyota and honda will gladly let other automakers into their factories, because they know that even if the others see what they do, the japanese are so far ahead of the others that they won't be able to implement things and just 'copy' them.

Leading implementation of lean will be a full time job.


User currently offlineEA CO AS From United States of America, joined Nov 2001, 13602 posts, RR: 61
Reply 2, posted (6 years 12 months 1 day 12 hours ago) and read 3542 times:
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Quoting ScrubbsYWG (Reply 1):
Lean is all about a culture change.

We're still attempting that culture change at my company, a place that is known for their innovative use of Lean. I've already been personally involved in a half dozen accelerated process redesign projects, and there's always the skeptic or two that can't (or won't) buy-in for change.



"In this present crisis, government is not the solution to our problem - government IS the problem." - Ronald Reagan
User currently offlineScarletHarlot From Canada, joined Jul 2003, 4673 posts, RR: 56
Reply 3, posted (6 years 12 months 1 day 6 hours ago) and read 3488 times:

Dear Lord. I come to A.net to get away from such blasphemous words and phrases. What's going to be on here next, green belt, black belt, or DFSS? Aieee!


But that was when I ruled the world
User currently offlineLTU932 From Germany, joined Jan 2006, 13864 posts, RR: 50
Reply 4, posted (6 years 12 months 1 day 6 hours ago) and read 3477 times:

Our team leads have to deal with the whole Six Sigma crap, so I can't say anything about it. However, we did have to deal with something called COPC and ISO 9xxx (don't remember what ISO it was) certification at one point, but while we discussed the whole thing ad nauseum, we all just cared less about it, didn't really put any attention to it and in fact, nobody came to give our company this COPC/ISO certification. It was constantly announced that the audit for it would be done, and they never came.

User currently offlineOBSMGR From United States of America, joined Aug 2007, 47 posts, RR: 2
Reply 5, posted (6 years 12 months 1 day 5 hours ago) and read 3465 times:

Ive gone through it 3 times.

Six Sigma is an attempt to teach common sense. Nothing more.

(And where the hell did the whole "black belt" crap come from?)



I just Googled your Yahoo :)
User currently offlineAirfoilsguy From , joined Dec 1969, posts, RR:
Reply 6, posted (6 years 12 months 1 day 4 hours ago) and read 3456 times:

Quoting ScarletHarlot (Reply 3):
Dear Lord. I come to A.net to get away from such blasphemous words and phrases.



I saw the thread title and thought I had logged onto the wrong website.   The company I am in now is just starting 6S. Getting our management to implement 6S is like teaching dinosaurs how to tap dance. Talk about a bunch of pissed off managers who don't want to try anything new. Every meeting we have had on 6S has turned into a finger pointing shouting match.

Quoting OBSMGR (Reply 5):
Six Sigma is an attempt to teach common sense. Nothing more.



Sure seems that way.

Quoting OBSMGR (Reply 5):
(And where the hell did the whole "black belt" crap come from?)



Didn't Jack Welch come up with that?

[Edited 2007-09-26 02:22:23]

User currently offlineGOCAPS16 From Japan, joined Jan 2000, 4346 posts, RR: 20
Reply 7, posted (6 years 12 months 21 hours ago) and read 3421 times:

Rhaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa!!!!!! 2 weeks of this crap here, it sucks. Do I learn new things? No...Is it wasting my time, yes. Apparently, I've been chosen to get my Green Belt qualifications. I don't see a point of this to do with maintenance. Boring, sucks, but oh well, maybe it'll help me in the long run. (yea right!)

[Edited 2007-09-26 09:44:12]

User currently offlineAirfoilsguy From , joined Dec 1969, posts, RR:
Reply 8, posted (6 years 12 months 19 hours ago) and read 3408 times:

Quoting GOCAPS16 (Reply 7):
but oh well, maybe it'll help me in the long run. (yea right!

It will, helps on the resume


User currently offline707cmf From France, joined Mar 2002, 4885 posts, RR: 29
Reply 9, posted (6 years 12 months 19 hours ago) and read 3403 times:

My former company introduced six sigma a year and a half ago with great results.

Well, by great results, I merely mean that I got laid off in December that same year ! Merry XMas from 6 Sigma, ho ho ho !

Cheers,

707 (much better in the new company anyway, so thanks a lot 6s)


User currently offlineFalstaff From United States of America, joined Jun 2006, 6104 posts, RR: 28
Reply 10, posted (6 years 12 months 17 hours ago) and read 3392 times:
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I used to work for Ford doing warranty claims analysis. We were Six Sigma and boy was it stupid. There were people in the company who would brag about being a six sigma blackbelt like it actually was cool or something. Then there were the people who were six sigma trainers. I always felt they would be the first to go in a tight budget. Now that Ford is not doing so well I wonder if those people are still there?

While I was there we had an ISO 9000 audit. That was dumb too. Our boss had us put our non compliant documents in our cars so the inspector wouldn't find them. Sounds like a Dilbert cartoon, doesn't it? We were technical a paperless office, but many times looking up info on the computer took longer than using paper manual. I never understood the ISO 9000 stuff. The boss kept telling us it was to prove what we did was what we said we did. But it was a lie because we didn't do what we said we did.



My mug slaketh over on Falstaff N503
User currently offlineAntdenatale From United Kingdom, joined Aug 2006, 178 posts, RR: 0
Reply 11, posted (6 years 12 months 7 hours ago) and read 3343 times:
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Six Sigma is more for the analysts within the business than anything else, now LEAN is something different and gaining a lot of momentum within the UK. The only company that has achieved 6 sigma is Motorola around 10 years ago.

Quoting Airfoilsguy (Reply 6):
Didn't Jack Welch come up with that?

The guy is my hero in the business world, when you can take a company like GE and turn it around to be number 1 in every market it has business in, you have to be some kind of great leader!

I do a fair bit of consultancy on quality systems and could explain the benefits to you in depth, however I would have to charge you £600 per day for my time
 Big grin  Wink  Big grin  Wink


User currently offlineFriendlySkies From United States of America, joined Aug 2004, 4106 posts, RR: 5
Reply 12, posted (6 years 12 months 3 hours ago) and read 3325 times:

I'm a co-op at GE, and while I don't directly work on LSS projects, a lot of the work I do is aimed at the fundamentals of the program (improving quality, decreasing cycle times, doing more with less sort of thing). GE has embraced LSS so much that it seems everything we do is focused on it...it sucks to do it sometimes, but the end results are well worth the effort. The downside is when people focus too much on "metrics" and whatnot, instead of what we're actually making with it.

User currently offlineGerardo From Spain, joined May 2000, 3481 posts, RR: 30
Reply 13, posted (6 years 11 months 4 weeks 1 day 21 hours ago) and read 3306 times:

We went from six sigma over lean sigma to a slightly adoption of lean sigma.

Good ideas, no question, but it has to be more than only a "new department". It's a cultural change. I have a lot to do with those black belts in my projects.

Gerardo



dominguez(dash)online(dot)ch ... Pushing the limits of my equipment
User currently offlineAndz From South Africa, joined Feb 2004, 8453 posts, RR: 10
Reply 14, posted (6 years 11 months 4 weeks 1 day 21 hours ago) and read 3302 times:
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My company is a GE distributor and GE live by Six Sigma. The whole colour belt thing could have been started by Jack Welch because in GE if someone is a Six Sigma Black Belt they are a rare and revered individual. Personally I have no idea what it is all about!


After Monday and Tuesday even the calendar says WTF...
User currently offlineCaptOveur From , joined Dec 1969, posts, RR:
Reply 15, posted (6 years 11 months 4 weeks 1 day 14 hours ago) and read 3269 times:

I always thought both were something cooked up by management consultants to justify their miserable existence.

User currently offlineTSV From Australia, joined Nov 1999, 1641 posts, RR: 5
Reply 16, posted (6 years 11 months 4 weeks 1 day 13 hours ago) and read 3254 times:

Yeah even McDonald's has a LSS program - only yesterday did I see their slogan :

"Time to Lean. Time to Clean."

(Extract Tongue from Cheek)



"I told you I was ill ..." Spike Milligan
User currently offlineMike89406 From United States of America, joined Mar 2007, 1467 posts, RR: 3
Reply 17, posted (6 years 11 months 4 weeks 1 day 13 hours ago) and read 3247 times:

Naval Aviation Maintenance (US Navy) is going through Sig Sigma, Lean, Process Improvement its been going on for over a year now (seminars, training teams coming up from San Diego, etc...). Here at Intermediate Maintenance Level Six Sigma, Lean etc...is strongly changing the ways we do maintenance on aircraft.

They are moving towards implementing the whole process in to Organizational Maintenance Level (Day-to-Day aircraft maintenance directly on the aircraft). Someday the whole Navy will be lean.


User currently offline2H4 From United States of America, joined Oct 2004, 8955 posts, RR: 59
Reply 18, posted (6 years 11 months 4 weeks 1 day 12 hours ago) and read 3243 times:
AIRLINERS.NET CREW
DATABASE EDITOR

Quoting Mike89406 (Reply 17):
Six Sigma, Lean etc...is strongly changing the ways we do maintenance on aircraft.

Are you able to elaborate at all? It would be interesting to hear some specific examples.


2H4




Intentionally Left Blank
User currently offlineRonglimeng From Canada, joined Oct 2006, 625 posts, RR: 0
Reply 19, posted (6 years 11 months 4 weeks 1 day 12 hours ago) and read 3239 times:

I don't know about Six Sigma, but I was responsible for the ISO 9001-registered quality program at my former employer (now out of business).

Most of the time I felt like I had been dropped off on some tropical island to convert the cannibals to Christianity. I kept the prayer books and the hymnals in good order and offered services 5 days a week and twice on Sundays. Generally I worked hard but was unsuccessful. I often wondered if I had been more of a "Billy Graham", whether I would have moved the program forward to a greater degree. But I doubt if even Billy could have converted that bunch.

People above have talked about "changing the culture" of an organisation. That sure isn't very easy to do, especially from the middle-to-lower rungs of management.

Call me selfish, but I had demonstrated a successful management technique in a company that I ran, I would be inclined to keep it a secret. CEO's who do publicise the secrets of their successes, probably know those secrets can't be easily transplanted elsewhere.


User currently offlineAirfoilsguy From , joined Dec 1969, posts, RR:
Reply 20, posted (6 years 11 months 4 weeks 1 day 12 hours ago) and read 3236 times:

Quoting Ronglimeng (Reply 19):
CEO's who do publicise the secrets of their successes, probably know those secrets can't be easily transplanted elsewhere.

Most do it for the money. My dad has been retired for about 7 years but people are still calling him up wanting him to be a consultant. He always declines, he tells them that he is retired for a reason. There is also big money to be made in books and seminars.


User currently offlineIFEMaster From , joined Dec 1969, posts, RR:
Reply 21, posted (6 years 11 months 4 weeks 1 day 12 hours ago) and read 3228 times:

Quoting Antdenatale (Reply 11):
The only company that has achieved 6 sigma is Motorola around 10 years ago.

Perhaps that's because they pretty much invented it.

Quoting Ronglimeng (Reply 19):
CEO's who do publicise the secrets of their successes, probably know those secrets can't be easily transplanted elsewhere.

 checkmark  Company culture has everything to do with it. and since both LEAN and 6S are generally about a change in culture, many companies find it hard to adapt. Ultimately, any good leader should be able to cast a vision, define the goals, and instill a culture that achieves them, regardless of LEAN, 6S, consultants, analysts etc.


User currently offlineMike89406 From United States of America, joined Mar 2007, 1467 posts, RR: 3
Reply 22, posted (6 years 11 months 4 weeks 1 day 12 hours ago) and read 3227 times:

Quoting 2H4 (Reply 18):
Quoting Mike89406 (Reply 17):
Six Sigma, Lean etc...is strongly changing the ways we do maintenance on aircraft.

Are you able to elaborate at all? It would be interesting to hear some specific examples.
2H4

There's nothing really classified about the process even for the military unless you start talking what some people work on, type of aircraft, ordnance systems etc...

They send most workers in affected workcenters to green belt training. But most of our changes have been in reducing the turn around time for a maintenance action from induction to completion for example: the tire shop receives a tire with used rubber they disassemble and do the required maintenance (replace o-rings, throw rim in parts washer etc...) in the past It may have taken 2 hrs ( a rough figure) and by the time everything is implemented people are trained work-center is re arranged to make it conducive to make the process faster it may take 30-45 mins of actual maintenance time in comparison to the previous figure.

There' s a lot more to it depending on the work-center and there are reports summaries etc..

But the point is to cut the fat out of an organization, and make everything streamline. The thing that has slowed us down in re-issuing something that the technicians are fixing in a quick manner is that the supply system can halt work on a particular item. So we place a part on the shelf until we receive the part sometimes though parts can come quick nothing is always consistent but supposedly thats what were working towards is consistency


User currently offlineSBBRTech From Brazil, joined Jul 2007, 722 posts, RR: 0
Reply 23, posted (6 years 11 months 4 weeks 1 day 11 hours ago) and read 3222 times:

Quoting Falstaff (Reply 10):
While I was there we had an ISO 9000 audit. That was dumb too. Our boss had us put our non compliant documents in our cars so the inspector wouldn't find them. Sounds like a Dilbert cartoon, doesn't it? We were technical a paperless office, but many times looking up info on the computer took longer than using paper manual. I never understood the ISO 9000 stuff. The boss kept telling us it was to prove what we did was what we said we did. But it was a lie because we didn't do what we said we did.

Haha, this sounds too much like us in the 1st years of ISO 9000:2000...then 9001, 9004....
Every post-certificate audition had my former boss trembling and shaking as a Bin Laden aidee during doomsday.
Once he sent all new techs to the most distant places in the airport so the audits wouldn´t ask them about norms and processes...



"I'm beginning to get the hang of this flying business" - C3PO
User currently offline2H4 From United States of America, joined Oct 2004, 8955 posts, RR: 59
Reply 24, posted (6 years 11 months 4 weeks 1 day 10 hours ago) and read 3210 times:
AIRLINERS.NET CREW
DATABASE EDITOR

Quoting Mike89406 (Reply 22):
But most of our changes have been in reducing the turn around time for a maintenance action from induction to completion

Interesting. Are you now tracking and posting average turnaround time, so people can see where they're at and where they need to be?

2H4




Intentionally Left Blank
25 Mike89406 : Yes actually average they're past showing average turnaround time I think that was done last winter. Now statistical data is being displayed onto wor
26 ScrubbsYWG : just a note i remember from my life in the 'lean manufacturing/six sigma' environment. My former boss went on a best practice tour of Research in Moti
27 Falstaff : I worked at a McDonalds in Eureka, Missouri (about 40 miles southwest of St. Louis) in 1992 and my manager used to say that all the time.
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