Lean Six Sigma Project

| January 28, 2016

Here are the readings for the course:

George, M. L., Rowlands, D., Maxey, J., & Price, M. (2004). The Lean Six Sigma Pocket Toolbook: A Quick Reference Guide to Nearly 100 Tools for Improving Process Quality, Speed, and Complexity. Columbus, OH: McGraw-Hill Companies. ISBN-13: 978-0071441193. SSM 874 01072014 y Management 2/9

Kotter, J.P. (2007). Leading Change: Why Transformation Efforts Fail. Boston, MA: Harvard Business Review. Product #:R0701J-PDF-ENG11p.

“Meet Minitab” Guide available under Course Materials on the NGS Portal.

Project Management Institute (2013). A Guide to the Project Management Body of Knowledge (PMBOK Guide). Newtown Square, PA: Project Management Institute. ISBN-13: 978-1935589679.

Rother, M., Shook, J., Shook J., & Womack, J. P. (2009). Learning to See: Value-Stream Mapping to Create Value and Eliminate Muda. Cambridge, MA: Lean Enterprises Institute, Inc. ISBN-13: 978- 0966784305 (LEI – www.lean.org).

Spear, S.J., & Bowen, H.K. (2006). Decoding the DNA of the Toyota Production System. Boston, MA: Harvard Business Review. Product #:2904-PDF-ENG13p, English PDF.

The Assignment

The deliverable of this assignment is an individual presentation that includes effective communication of Lean Six Sigma Project at Jamba Juice, Robek’s, Starbucks, Dunkin Donuts, or a similar food retail operation. Follow the “Learning to See” principles to create the Current State and Future State Value Stream Maps (VSM). Apply the Six Sigma DMAIC (Define, Measure, Analyze, Improve, and Control) phases for problem solving. Following are the key deliverables for the project presentation:

1) Project Plan: Create an effective Project Plan using Microsoft Project (preferred) or MSExcel or MSWord. Apply Project Management techniques such as Gantt Chart and Critical Path. Apply PMBOK areas to plan your project effectively.

2) Gemba Walk / Site Visit: Go to a Jamba Juice, Robek’s, Starbucks, Dunkin Donuts, or a similar retail food operation. Minimum two visits of 1 hour each are expected during the course of the project i.e. first visit for creating the Current State VSM and second visit to execute the data collection plan. It is optional to engage staff members of the organization in your discussion, if at all possible.

3) Problem Statement: Based on your observations, create a clear and compelling problem statement e.g. excessive lead time.

4) Current State VSM: Create a Current State VSM showing product and information flow, using the diagramming protocols outlined in Learning to See (Rother and Shook).

5) Data Collection: Create data collection plan based on cause hypotheses for the problem. Data collected may include demand rate data, cycle time data, lead time data, and product type data. Create a lead time ladder in the VSM. Calculate takt time. Identify each data element by type (discrete or variable) and whether it is a factor or an outcome. Note: Use the provided “dummy data” if needed.

6) Data Analysis: Analyze root causes of problem using the Minitab Statistical Software or another advanced statistical software. Data analysis may include various statistical techniques listed in “Meet Minitab” guide e.g. correlation, regression, and/or DOE (Design of Experiments).

7) Future State VSM: Create a Future State VSM based on the application of lean and six sigma principles.

8) Presentation: Deliver an impactful and visually-engaging presentation to class using PowerPoint or another presentation software. The class attendees will play the role of senior leadership of the organization and ask challenging questions to the presenter. The presentation shall include but not limited to Organizational Background Info, Problem Statement, VSM, DMAIC phases, statistical analysis results, and recommendations for process improvement.


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