Department of Defense Voluntary Protection Programs Center of Excellence Development, Validation, Implementation and Enhancement for a Voluntary Protection Programs Center of Excellence (VPP CX) Capability for the Department of Defense Department of Defense Voluntary Protection Programs Center of Excellence Lean/Six Sigma & VPP Development, Validation, Implementation and Enhancement for a Voluntary Protection Programs Center of Excellence (VPP CX) Capability for the Department of Defense

Objectives After this training you will be able to: –Describe Six Sigma and Lean approaches –Identify the five steps of the Six Sigma Process –Describe Lean 5S –Understand how Lean/Six Sigma compliment VPP –Discuss the role of Leadership in Lean/ Six Sigma and VPP.

Lean and Six Sigma Six Sigma is a system of data driven statistical process control Lean focuses on process flow and eliminating waste Lean and Six Sigma compliment each other in a culture of continuous improvement.

Department of Defense Voluntary Protection Programs Center of Excellence Development, Validation, Implementation and Enhancement for a Voluntary Protection Programs Center of Excellence (VPP CX) Capability for the Department of Defense Six Sigma

Six Sigma is a: –Goal where organizations should operate at less than 3.4 defects per million opportunities –Philosophy dedicated to reducing defects and variations in processes, products and services –Metric where communication is more effective by using the same standards throughout the organization.

Six Sigma Process There are five steps to the Six Sigma process: –Define Phase –Measure Phase –Analyze Phase –Improve Phase –Control Phase.

Six Sigma – Define Phase The Define Phase objective is to understand the requirement, goal(s) and current process –Define the safety or health requirements and goal(s) –Define how the current process works.

Six Sigma – Measure Phase The Measure Phase objective is to assess current safety performance –Define incident, near misses, severity, potential hazard, etc. –Develop data collection system, gather incident information and measure baseline performance –Identify areas with most incidents or highest risk (i.e. the critical few).

Six Sigma – Analyze Phase The Analyze Phase objective is to determine which safety problems to solve in what order –Evaluate and prioritize work activities associated with incidents –Determine root causes and possible countermeasures –Identify and prioritize gaps in the current process.

Six Sigma – Improve Phase The Improve Phase objective is to identify and implement optimal change solutions –Evaluate and prioritize corrective /preventive measures –Eliminate incidents through process re-design and error proofing –Deploy effective corrective/preventive measures.

Six Sigma – Control Phase The Control Phase objective is to sustain, enhance and improve process performance –Continuously evaluate and improve, using the Plan, Do, Check, Act (PDCA) Cycle.

Six Sigma & VPP

Six Sigma Mapped to Stages & Elements of VPP

Department of Defense Voluntary Protection Programs Center of Excellence Development, Validation, Implementation and Enhancement for a Voluntary Protection Programs Center of Excellence (VPP CX) Capability for the Department of Defense Lean

Process management philosophy –Eliminate wastes –Smooth and efficient work flow The Original Seven Wastes OverproductionDefectsTransportationWaiting OverprocessingInventory Motion Evolving thoughts on waste –Safety: “Unsafe work areas create lost work hours and costs.” –Skills: "It is only by capitalizing on employees' creativity that organizations can eliminate the other seven wastes and continuously improve their performance."

Lean 5S Process Lean 5S originated in Japan in the 1960’s as a technique of good housekeeping and workplace organization The 5 S’s are: –SORT= Go through everything –keep only what is needed –STORE= A place for everything –in a way that promotes good work flow –SHINE= Clean everything –STANDARDIZE= Make standards visually obvious – everyone does things the same way –SUSTAIN= Keep it that way.

Good Floor Examples of 5S

Good Office Examples of 5S

Department of Defense Voluntary Protection Programs Center of Excellence Development, Validation, Implementation and Enhancement for a Voluntary Protection Programs Center of Excellence (VPP CX) Capability for the Department of Defense Lean/Six Sigma & VPP

Keys to Lean / Six Sigma Success: –Management Commitment Time and Resources Clear Performance Goals Visible Leadership. –Employee involvement –Training and Tools –Improvements Driven by Data –Systematic Processes –Plan-Do-Check-Act –Continuous Improvement –Support from qualified professionals.

Lean and Six Sigma Teach Tools & Techniques That Can Support and Reinforce VPP

Department of Defense Voluntary Protection Programs Center of Excellence Development, Validation, Implementation and Enhancement for a Voluntary Protection Programs Center of Excellence (VPP CX) Capability for the Department of Defense Leadership Role

Expect Safety to be part of every Lean / Six Sigma event Support both -time and resources Use skills acquired for Lean / Six Sigma for VPP initiatives.

Leadership Role Provide cross training opportunities for Lean / Six Sigma and Safety and Health professionals Personally participate in Lean / Six Sigma and VPP events. “Lead by Example”

Summary In this session you learned about: –Lean and Six Sigma approaches –The five steps of the Six Sigma process –Lean 5S –How Lean / Six Sigma compliments VPP –The role of Leadership in Lean / Six Sigma and VPP.