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At PROCESS SOLUTIONS
INTERNATIONAL, we know the theory of Lean Manufacturing and Six Sigma. More important to you, we understand
how to apply "the tools" and teach them in the common sense, practical approach that you need for the success of your business.
THE PSI INTEGRATED SIX SIGMA and LEAN APPROACH
At the core of our approach is the understanding
that the majority of Six Sigma and Lean Deployments fail because organizations are not taught how to properly select projects
based on the needs of the business and its customers, how to facilitate and lead teams, and how to effectively use project
management tools (particularly Critical Path Methodology) to properly manage resources. Studies have repeatedly proven that
projects and deployments do not fail due to a lack of understanding of the tools and the "hard" skills of Six Sigma and Lean
- they fail due to a lack of understanding of the "soft" skills - the interpersonal aspects of Six Sigma and Lean.
Through
our approach of teaching and mentoring the skills of Team Leadership / Facilitation, Project Management, Six Sigma and Lean
Manufacturing (Toyota Production System) and integrating them with your Organizational Culture, Corporate Vision, Business
Strategies and Operational Tactics, we enable you to receive the full benefits, advantages and results of Six Sigma and Lean
Manufacturing.
Your First Step: Business
Assessment
First - don't let the word "assessment" scare you. If you skip this
step and get it wrong, it will cost you a lot of time, money and effort to get back on track. Get it right, and the results
will be fast and dramatic. It's a critical step in the success of your deployment. And it need not be a long and drawn
out "science project." It does, however, need to be honest, accurate, concise and complete.
Your Business
Assessment is conducted through personal interviews of selected individuals, formal surveys, the gathering of existing
business performance data and information, and a tour of the organization. Your assessment includes:
Customer Satisfaction: Retention / Loss, Complaints, Returns / WarrantyBusiness
Systems: Strategies, SWOT, Core Competencies and Performance IndicatorsBenchmark Analysis:
Competitive and Best-in-PracticeCulture: Team Skills, Knowledge, Use, and Acceptance of
Change and ImprovementSix Sigma / Lean Utilization: Rapid Plant Assessment, Six Sigma and
Lean IndicatorsAssessment Analysis, and Presentation to Executive Team with PSI Recommendations The Second Step: Champion / Executive Training, Deployment Planning and Executive Actions The selection
of Champions and their training along with Senior Executives is the second critical step on the road to success for your
deployment. During the first three days of this five day workshop, you will learn the key aspects of Six Sigma and Lean Systems.
Over the last two days of the workshop, the information gained from the PSI Business Assessment will be presented and used
to develop your plan for deployment. The Champions and Executives will identify Action Items they need to address, create
their plan and initiate projects at their level. Included in the Deployment Plan will be the initiation of a Steering Committee
and the selection of the Pilot Value Streams and potential project(s).Your Third Step:
Training Your Professionals and Pilot Projects
Your
training will start with Value Stream Mapping with Cost of Waste and Poor Quality Analysis. During the first week of training,
students will document the selected Value Stream(s) Current State Map and identify the locations and amounts of waste, categorized
by the Seven Deadly Wastes (Defects, Overproduction, Transportation, Waiting,
Inventory, Motion, Processing), with an in-depth look at the sources of Defects and the associated
Cost of Poor Quality (ppm, dpu, cost of scrap/rework, etc.). Both Manufacturing and Transactional Value Streams are identified
and investigated. From this detailed information, your Professionals will be able to prioritize and initiate projects to
improve the Value Streams, using the tools and skills they have learned, to reduce Value Stream Variation (Six Sigma) and
improve Value Stream Flow (Lean/TPS).
While learning Six Sigma DMAIC
(Define, Measure, Analyze, Improve, Control), you will gain and in-depth understanding of Six Sigma. From the basic tools
of Pareto Charting, Process Mapping, Ishakawa Cause and Effect Diagrams, FMEA, bar/line charts, and control charting, to
the more complex topics of Optimization via screening and modeling DOE (Design of Experiments) and the extremely powerful
tools of Design for Six Sigma, you will learn easy to use and understand
software and methods that will allow you to improve any system or process, manufacturing or transactional.
You'll
also get the practical application of the tools, both in the classroom, in fun and interesting materials and exercises that
help you learn and apply the tools and methods, and while working on real-time projects that your instructors and mentors
will guide you through to completion and certification. In many cases, your first projects will achieve your return-on-investment
before you have completed your training.
CUSTOMIZED TO MEET YOUR NEEDS
We also
understand that learning and applying the tools and concepts of Lean Manufacturing and Six Sigma require more than a one-size-fits-all
approach to the training and mentoring of our clients. We will work closely with you to customize your training materials
and approach to implementation so that you get the very most from your initiatives.No matter
the industry or process, regardless the success of your past efforts, we have the people and the capabilities that will get
you started from scratch or that will enable you to receive more return from your existing, or past, process improvement initiatives.
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