1. 6S Simulation - K. Berry 1/29/2010 1 6S Simulation

2. 6S Simulation - K. Berry 1/29/2010 2 Instructions to the Class Worker  Gather White, Yellow and Blue sheets of paper  Paper clip the sheets together  Place in a folder  Place post-it on the outside of the folder  Place folder and contents on the chair (to be picked up by a delivery person) Manager  Create a spaghetti diagram: Draw a rough draft of the room layout identifying the location of the supplies used in the simulation Draw a rough draft of the room layout identifying the location of the supplies used in the simulation As Participant #1 walks the process, trace his/her footsteps on the spaghetti diagram As Participant #1 walks the process, trace his/her footsteps on the spaghetti diagram

3. 6S Simulation - K. Berry 1/29/2010 3 Instructions to the Class  Efficiency Expert #1 Count the number of steps Person #1 travels from beginning to end in the process. Count the number of steps Person #1 travels from beginning to end in the process.  Efficiency Expert #2 Track how much time Participant #1 takes to do the entire process Track how much time Participant #1 takes to do the entire process Track how much time is wasted waiting and/or searching Track how much time is wasted waiting and/or searching  Customer Do a quality inspection on the finished product against the sample provided to you by the Instructor Do a quality inspection on the finished product against the sample provided to you by the Instructor  Co-workers (Rest of Class) Identify the 8 Forms of Waste in our process Identify the 8 Forms of Waste in our process Identify possible ideas for improvement Identify possible ideas for improvement

4. 6S Simulation - K. Berry 1/29/2010 4 What Are the Results?  Worker How did the process feel to you? How did the process feel to you?  Manager What does the spaghetti diagram show us? What does the spaghetti diagram show us?  Efficiency Expert #1 How many steps did it take to do the process? How many steps did it take to do the process?  Efficiency Expert #2 How much time did the entire process take? How much time did the entire process take? How much time was wasted waiting and/or searching? How much time was wasted waiting and/or searching?  Customer Did the product meet or exceed the customer’s requirements (quality inspection)? Did the product meet or exceed the customer’s requirements (quality inspection)?  Rest of Class Identify forms of waste in the process Identify forms of waste in the process Include possible ideas for improvement Include possible ideas for improvement

5. 6S Simulation - K. Berry 1/29/2010 5 Where is the Waste?  What forms of waste can we identify in our process? Wasted Human Talent – Wasted Human Talent – Defects – Defects – Inventory – Inventory – Over Producing – Over Producing – Waiting – Waiting – Motion – Motion – Transportation – Transportation – Over Processing – Over Processing –

6. 6S Simulation - K. Berry 1/29/2010 6 Quantifying the Results BeforeAfterImprovement Number of Defects Excess Inventory Over Producing (scrap) Waiting Motion/Transportation * Capture on Flip Chart Paper

7. 6S Simulation - K. Berry 1/29/2010 7 How Can We Use 6S to Improve? 1. Sort – Separate the needed from the not needed 2. Straighten – A place for everything and everything in its place 3. Scrub – Ensure everything is in perfect working condition 4. Standardize – Determine the best method – visual queues, labeling, etc. 5. Sustain – Develop Standard Work 6. Safety – Safety first at all times

8. 6S Simulation - K. Berry 1/29/2010 8 Instructions to the Class  Now that you have identified the waste and the opportunities for improvement in the process Put your recommended improvements in place Put your recommended improvements in place We’ll run the simulation a second time We’ll run the simulation a second time Then we’ll measure the results… Then we’ll measure the results… ….and celebrate our success!!

9. 6S Simulation - K. Berry 1/29/2010 9  Following slides are Facilitator Instructions

10. 6S Simulation - K. Berry 1/29/2010 10 Facilitator Instructions – Set Up  The placement of the materials is probably the most critical piece of this very simple simulation. The entire simulation takes 10-15 minutes max.  Spread the paper, file folders, post-its, supplies (boxes of paper clips) randomly around the room. Make certain nothing is in the sequence that it will be used. For example, don’t place the pieces of paper together in one location (motion).  The red folders are mixed in with various other colored folders (excess inventory) in a pile (searching).  Paper clip boxes are in with various other supplies (searching). However, all of the boxes are empty (defect) so the team will have to ask you to supply them with a new box of paper clips (waiting).

11. 6S Simulation - K. Berry 1/29/2010 11  Have a quality check at the end of the process. This is to show students the value of standard work.  The final product should meet the following criteria:  Sheets of paper (one of each color)must be in the following order: 1. 1 Blue Sheet 2. 1 White Sheet 3. 1 Yellow Sheet  Paper clip sheets together per the example below  The folder must be RED  The post-it must be on the upper left corner of the folder Facilitator Instructions – Set Up

12. 6S Simulation - K. Berry 1/29/2010 12 Standard Work – Handout for the Customer Create a sample folder that is given to the “Customer” during the simulation. Ask that the Customer not share this information with the rest of the class.

13. 6S Simulation - K. Berry 1/29/2010 13 Quantifying the Results BeforeAfterImprovement Number of Defects Excess Inventory Over Producing (scrap) Waiting Motion/Transportation Create this chart on Flip Chart Paper prior to the start of the class

14. 6S Simulation - K. Berry 1/29/2010 14 Facilitator Instructions - Spaghetti Diagram Paper Clips Post its X X Before After Sample – The class should create this during the simulation

15. 6S Simulation - K. Berry 1/29/2010 15 Facilitator Instructions - Waste in the Process  Wasted Human Talent – The team wasn’t involved in designing the process The team wasn’t involved in designing the process  Defects – Paper clips were missing; not meeting customer requirements (lack of standard work) Paper clips were missing; not meeting customer requirements (lack of standard work)  Inventory – Excess folders (any folder that isn’t red) Excess folders (any folder that isn’t red)  Over Producing – Having more sheets of paper in the folder than is required Having more sheets of paper in the folder than is required  Waiting – For new box of paper clips For new box of paper clips  Motion – Searching for the right folder; paper clips mixed in with supplies. Searching for the right folder; paper clips mixed in with supplies.  Transportation – Carrying paper, paper clips etc. to where they are needed (at the chair). Carrying paper, paper clips etc. to where they are needed (at the chair).  Over Processing – More pieces of paper in the folder than required. More pieces of paper in the folder than required.

16. 6S Simulation - K. Berry 1/29/2010 16 Facilitator Instructions - 6S Improvements  Sort - Purge items that are not needed (i.e. remove colored folders that are not part of the process) Purge items that are not needed (i.e. remove colored folders that are not part of the process)  Straighten - Determine an appropriate place for everything (co-locate) Determine an appropriate place for everything (co-locate) Ensure the supplies are placed in the sequence they will be used. Ensure the supplies are placed in the sequence they will be used.  Scrub - Make certain everything is in working order (paper clips are available, etc) Make certain everything is in working order (paper clips are available, etc)  Standardize - Add labeling & visual controls Add labeling & visual controls Develop work instructions Develop work instructions  Sustain - Develop standard work Develop standard work  Safety -