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AGENDA FOR 6S COUNCIL EUROPE 3.4.2003

PROGRESS IN IMPLEMENTATION GB TRAINING ONGOING PROJECTS OPERATING PLAN VISION 1,3,5 YEARS NEXT STEPS PROPOSAL FOR MASTER THESIS SUBJECT: QUALITY COST (COPQ) COUNTING AND REPORTING SYSTEM AND PROCEDURES TO DRIVE SIX SIGMA PROJECT SELECTION. AGENDA FOR 6S COUNCIL EUROPE 3.4.2003.

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AGENDA FOR 6S COUNCIL EUROPE 3.4.2003

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  1. PROGRESS IN IMPLEMENTATION GB TRAINING ONGOING PROJECTS OPERATING PLAN VISION 1,3,5 YEARS NEXT STEPS PROPOSAL FOR MASTER THESIS SUBJECT: QUALITY COST (COPQ) COUNTING AND REPORTING SYSTEM AND PROCEDURES TO DRIVE SIX SIGMA PROJECT SELECTION AGENDA FOR 6S COUNCIL EUROPE 3.4.2003

  2. Benefits from 6S projects =1500 000€ (Benefits/costs=3.5) 18 Green belts trained (5 Lahti, 5 Hollola, 2 Laitila, 2 Tooling, 2 Helmond, 2 Pécs) 30 Greenbelt projects finished by 31.12.2003 or 750 000€ 6 Black belt projects finished by 31.12.2003 or 750 000€ Training material created for GB and awareness training Define procedures how individual 6S projects will be reported so that the results can be utilized throughout whole company TARGETS 2003 EUROPE

  3. 6S OPERATIONALIZING PLAN EUROPE SIX SIGMA VISION +NEED FOR 6S TARGETS/ EXPECTATIONS FOR BB+GB COST OUT YIELD… P A 6S COUNCIL CHAMPIONS ON BOARD MBB NETWORK GE SUPPORT C D SUPPORT INFRASTRUCTURE TARGETS/ EXPECTATIONS 6S+MBB 1st Wave 2 BBs Kim + Wille Choosing 5 GB’s/Plant FEEDBACK FROM GE/Marcel Present state analysis Benchmarking 6S council+BBs RESOURCES Project selection Assign high leverage projects for BBs+GBs Ensure early wins DEPLOYMENT INITIAL PLAN PROJECTS TRAINING GB Training Awareness training CAP for BBs DFSS/DMAIC Measure progress MEASUREMENT+ TRACKING COACHING MBB coaches + facilitates BBs + GBs REPORT TO 6SCOUNCIL+PVI REPORTING ASSESSMENT+ REVIEW Results reported to 6SC ASSESSMENT CRITERIA Reward good results successes training/project completion REWARD EARLY SUCCESS IMPROVE DEPLOYMENT PLAN TRANSLATE RESULTS NEXT PROJECTS

  4. 21 GB selected (9 Lahti, 5 Hollola, 2 Tooling, 1 Laitila, 3 Helmond, 1 Pécs) 18/21 GB’s have project GB training material for 1st module created 1st module of GB training 8.-9.4 (Jan Martens/GEP, AK, WV as trainers) Supporting Kim, Wille, Janna and Johanna Annual plan created 1-3-5 years vision created Quality research =>results by 11.4, America+Europe+China next PROGRESS IN IMPLEMENTATION

  5. GB PROJECTS

  6. Wille Vanessa A+B combinations =>testing+analyzing Jacqueline A+B USW and combinations =>testing+analyzing A new project is needed Kim Foil positioning improvement in Jacqueline window =>Target finished at W17 Starting project: Bright dots in IMD process Janna DFSS: 2S IMD Window in Hitchiker Johanna DFSS: Implementing SPC Development team projects 3 large BB projects (Niina) ONGOING BB PROJECTS

  7. OPERATING PLAN

  8. CURRENT STATE ANALYSIS – INDIVIDUAL LEVEL

  9. SIX SIGMA CAPABILITY CURRENT STATE ANALYSIS Six Sigma Excel- lence Six Sixma Institu- tionalized No experi- ence Some experi- ence Experi- ence DFSS NOW 1 YEAR 3 YEARS 5 YEARS DMAIC CAP LEAN SIX SIGMA BB

  10. PROCESSES WHERE 6S HAVE BEEN APPLIED Pad printing Painting USW Bezel Assembly SPC SCM Injection molding IMD IML insert Assembly DFSS DMAIC BB

  11. INTERNAL FOCUS ALSO EXTERNALLY Important CTQ alignment with company goals and external CTQ’s SIX SIGMA AT SUPPLIER/ CUSTOMER 6S- TRACKER SOFT- WARE Important Impact of project CTQ FLOWDOWN FROM COMPANY GOALS Important There are projects Number of projects PROJECTS CHOSEN BASED ON FACTS COPQ REPOR- TING AND SELECTION CRITERIA Project scope • In addition: Mission critical projects • Projects derived directly from goals PROJECTS CHOSEN BASED ON FEELING OR EMERGENCY Project scope • In addition: Complete processes, technologies, design and verify new processes, SCM, lean, factory level projects • Translating results • Create and disseminate best practices Project scope Single product or part of simple process Production processes

  12. 1-YEAR (2003) – Re-implementation of Six Sigma Company level: Beginning 6 BB projects, 30 GB projects, 5 DFSS projects Simple projects, single product/part of simple processes, production projects, some DFSS projects Beginning to use Six Sigma metrics and reporting Individual level: Beginning mainly 1-3 project experience for GB’s and BB’s, people need lot of support and coaching COPQ (+cost/benefit) counting and reporting implemented to drive six sigma project selection Rigorous review process implemented 1st GB training organized => 20 GB trained people Awareness of people have been raised – basic understanding 3-YEAR (end of 2005) - Institutionalizing Company level: Experience from over 100 projects Complete processes, technologies, design and verify new processes, SCM, lean, factory level projects, translating results Create and disseminate best practices throughout EIMO Six Sigma targets are aligned with company goals and CTQ’s Some experience with Six Sigma at supplier/customer Six Sigma Cook Book created Individual level: 20 GB’s with more than 10 projects experience, 10-20 GB some with 5 project experience, some in the beginning, 3-5 BB’s with more than 10 project experience Reporting COPQ, improvement results etc. part of daily life Capability to train all Six Sigma tools and resources internally Six Sigma awareness training part of new people introduction, all people have basic understanding Systematic career development for Six Sigma people Six Sigma has been institutionalized and has gained wide acceptance as key improvement methodology Benefit/cost ratio >4 5-YEAR (end of 2007) – Excellence in Six Sigma Company level: Experience from over 200 projects, 6S widely applied throughout company Capability to execute Six Sigma improvement widely in all processes (business and manufacturing) Benchmarking and disseminating best practices widely in use Metrics and reporting systems extensively used and understood throughout company SIX SIGMA VISION

  13. Proposal for Master thesis subject Define what and how (principles) will be counted for e.g. Internal COPQ (Scrap, rework, inspection, downtime, delivery inaccuracy, capcity loss…) External COPQ (Reclamations, …) How COPQ will be reported By products By processes By teams By technologies Daily, weekly, monthly… Where this information can be mined Define who should be interested in COPQ What system is used in reporting =>Power Play Procedures how COPQ information drives Six Sigma project selection We wiil be able to choose BB-projects that have biggest impact We will be able to choose smaller (more manageable) projects for GB’s Procedures how to report impact of Six Sigma projects We will be able track and report impact of 6S projects (cost/benefit info) COPQ/COST/BENEFIT COUNTING/TRACKING SYSTEM

  14. GB training module 2 Champion awakening training, choosing champions Project selection procedures (Antti, Niina, Marko) Start COPQ counting/reporting project (MSc thesis??) GB project definitions Project review&progress control with Kim, Wille, Janna, Johanna and GB’s Awareness training Create visibility for Six Sigma =>News letter, awareness training, 6S afternoon NEXT STEPS

  15. SIX SIGMA – WHO DO WHAT? SIX SIGMA AT CUSTOMER SIX SIGMA AT SUPPLIER Compli- cated process Product Simple process Techno- logy DFSS BB BB BB BB BB MBB MBB MBB GB DMAIC GB BB GB CAP BB MBB MBB LEAN SIX SIGMA BB BB MBB BB

  16. 6S RESOURCES

  17. SIX SIGMA EUROPE ORGANISATION Timo Seppä Seppo Jaakkola Petri Virtanen Minna Alitalo Marko Salli 6S COUNCIL EUROPE MBB+CHAMPIONS OPERATIONALIZING + 6S STRATEGY LAHTI HOLLOLA TOOLING LAITILA HELMOND PÉCS S U P P O R T M B B + C Wille Viittanen Kim Gustafsson Janne Martin? Katja Äärilä? M.S./F.N/H.N? BB BB BB BB BB GB GB GB GB GB GB

  18. FEED BACK/REVIEW MECHANISM Regular 6S council meetings timetables agreed => 1/month Suggested agenda for meetings Progress against operationalizing plans, achievements and concerns Status of 6S projects, achieved results Visitor presenting his/her project Recognition New ideas for 6S projects Input to future plans Other, what? MBB reviews BB and GB progress 1x/1-2 weeks Agenda for meetings BB+GB meeting 4x/year => for developing our Six Sigma approach and share experiences MBB team meeting (Eimo, Fibox, Lego, Grundfos) Reporting to Pete GE Support/Mentoring HOW TO TRACK PROGRESS

  19. HOW TO TRACK PROGRESS – STATUS OF ALL PROJECTS PROJECT CHARTER

  20. HOW TO TRACK PROGRESS – INDIVIDUAL PROJECTS

  21. 18 Green belts trained (5 Lahti, 5 Hollola, 2 Laitila, 2 Tooling, 2 Helmond, 2 Pécs) Internal search =>how? =>Virpi Requirements: Selfmotivated, interest towards improvement/6S Possibility to do GB projects also after training Basis OK (English, computers, preferably knowledge of production and/or improvement, studies) Diversified group of people (mold, injection, painting, assy…) Short interview Production managers to champion course Management participation (at least opening and closing sessions) SELECTING+TRAINING GB’s

  22. Choose 5 GB’s for Lahti and Hollola, 2 for Tooling, 2 for Laitila, 2 for Helmond, 2 for Pécs =>18 GB’s Training: selfstudy CD-ROM/digital training 2 x 2 days GB training at Lahti Trainers: Marcel Kranenburg/GE Antti Kontio MBB, Wille Viittanen+Kim Gustafsson BB Time: 1st training week 11 (10.-14.3) in Lahti =>check winter holiday plans 2nd training week 14 (31.3-4.4) 3 weeks of project work between training Projects must be selected for participants =>1st priority 1st 2 days is introduction to Six Sigma, DMAIC and 12-steps, some 6S Tools 2nd 2 days going into tools, DMAIC steps 1-3 must be completed before joining 2nd training TRAINING PLAN

  23. Big strategic projects? =>6S COUNCIL BB projects? Co-ordinated by Antti GB projects? Co-ordinated by Antti Development/R&D 6S projects? =>Niina Pareto projects –they are working well in Hollola with Kim and Tomi =>continue with them What to do when there is lack of BB’s or GB’s? How to get initiatives? How to process initiatives? How to reward initiatives? WHERE PROJECTS COME FROM

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