Page 109 - Lean six sigma demystified

88 Lean Six Sigma DemystifieD

ExErcisEs

1. Use the 5S principles on one of your most messy production or service delivery
processes.

2. Hang pedometers on your workers to get a sense of how far they travel in a
given day.

3. Diagram the spaghetti-like travel in one work area that seems to require too
much movement of people or materials. How would you start moving machines
and workstations around right now to create a smoother flow with less travel?

4. Map the value stream in one mission-critical process using the QI Macros Value
Stream template. Figure out the cycle time, changeover time, wait time, work in
progress, and so on, so that you fully understand how the process works. Iden-
tify the value-added and non-value-added activities in this process.

5. Redesign the work flow into cells using one-piece flow, pull, and kanban.
A. How can you create U-shaped work cells?
B. How can you reduce the movement of people or materials?
C. What machines can you right-size?

6. Develop a value-added analysis. Using a process flowchart, have participants do
a value-added flow analysis of the macro process using the QI Macros value-
added flow analysis template. Where in their existing process is most of the
wasted (idle) time and rework? What improvements could they initiate to elimi-
nate the waste?