1. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Lean Six Sigma Post-it Game

2. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 1 Set Up We are a company that delivers Catapult Launch distances. Company Information - -yyyy Functional Areas that can represent any transactional or manufacturing function within an organization -xxxx Product Lines/Plants/Sales and Marketing that produce a: service, information, or part -A Quality Department to check our work 1 person per product line -A Catapult launch area 1 person to launch 1 person to record distance and return ball -Delivery personnel – to deliver post-its from one functional area to another and to Quality and Catapult Launch -A manager that over sees the operation

3. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 2 Layout and Flow Function 1 Quality 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 12 34 Catapult 1 Function 2 Function 3Function 4 11 Product Lines Launcher Measurer/Retriever

4. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 3 Layout and Flow Quality 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 12 34 Catapult 1 gRaNuLaTe dRy cOmPrEsSiOn wEiGh 11 Launcher Measurer/Retriever

5. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 4 Product Process in Batches of 5 wgdcERROIaymGNPhurLEasTSeIOnwgdcERROIaymGNPhurLEasTSeIOn wgdcERROIaymGNPhurLEasTSeIOnwgdcERROIaymGNPhurLEasTSeIOn wgdcERROIaymGNPhurLEasTSeIOnwgdcERROIaymGNPhurLEasTSeIOn wgdcERROIaymGNPhurLEasTSeIOnwgdcERROIaymGNPhurLEasTSeIOn wgdcERROiaymGNPhurLEasTSeiOnwgdcERROiaymGNPhurLEasTSeiOn

6. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 5 Layout and Flow Quality 1 2 3 4 1 2 3 4 1 2 3 4 12 34 Catapult 1 gRaNuLaTe dRy cOmPrEsSiOn 11 Launcher Measurer/Retriever 1 2 3 4 wEiGh wEiGh gRaNuLaTe dRy cOmPrEsSiOn wEiGh gRaNuLaTe dRy cOmPrEsSiOn wEiGh gRaNuLaTe dRy cOmPrEsSiOn gRaNuLaTe dRy cOmPrEsSiOn wEiGh gRaNuLaTe dRy cOmPrEsSiOn

7. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 6 Customer and Business Requirements Customer Requirements Delivery Quantity -25 launch distances Delivery Time -<= 5 minutes for all 25 launch distances Launch Distance -Lower Specification Limit (LSL) = 200 cm -Upper Specification Limit (UCL) = 220 cm Distance Capability -Cpk: >=1.33 Business Requirements Deliver on Customer Requirements Work in Process (WIP) -No more than 1 at any one Function or Quality at anyone time Labor Costs -As low as possible Optimal process velocity

8. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 7 Data Collection

9. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 8 Post-It Improvements Measures -Cycle-time (< 5 mins.) -Work-in-Process (1) -Throughput (25) -Labor Costs (low) ppppppp -Post-it Defects (0) thhhhthththththththth pppp -Catapult Defects (1.33) Root Cause -Complexity Distance Traveled Functional Silos -Work Imbalance -Long Change Over- times pppppp -Lack of SOP’s -Standards Ill-defined pppp -Poor Measurement System Analysis (MSA) results -Lack of Training -Wrong Input settings -No SOP’s - Not Trained Solutions -Change Layout -Create Value-Streams -Cross-Train -SMED (Single Minute Exchange of Die -Create SOP’s and Train -Work w/Customer – Correct Standards -Fix MSA llll -Ensure SOP’s correct – train -DOE – Correct settings -Create SOP’s and Train

10. Copyright © 2001-2005 Six Sigma Academy International, LLC All Rights Reserved Presentation NamePg 9 The following are trademarks and service marks of Six Sigma Academy International, LLC: Breakthrough Lean ®, Breakthrough Strategy ®, Breakthrough Value Services ®, Breakthrough Change Strategy SM, Breakthrough Design SM, Breakthrough Diagnosis SM, Breakthrough Execution SM, Breakthrough Sigma Lean SM, Breakthrough Six Sigma SM, Breakthrough Software Design SM, FASTART SM, Six Sigma Gold Belt TM, SOLVING YOUR BUSINESS PROBLEMS FOR THE LAST TIME SM. Six Sigma is a federally registered trademark of Motorola, Inc. MINITAB is a federally registered trademark of Minitab, Inc. SigmaFlow is a federally registered trademark of Compass Partners, Inc. VarTran is a federally registered trademark of Taylor Enterprises. Six Sigma Academy International, LLC 8876 East Pinnacle Peak Road, Suite 100 Scottsdale, Arizona 85255 Tel. (480) 515-9501 Fax (480) 515-9507 www.6-sigma.com