The Lean6leadership's Podcast: Recent Episodes

Lean6leadership

Welcome to Lean6leadership that is Lean with the number six leadership dot com. Where I discuss the ins and outs of Quality Engineering/management, Program/Project management, and how to apply it to your life. I am a certified Six Sigma Master Black Belt, and a recovering Project Management Professional. I have been in manufacturing in one role or another for the last 20 years.

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In this episode, we will discuss 5S

Item 1: Why 5S

  1. Image of professionalism
  2. Find stuff
  3. Cost control

Item 2: When 5S

  1. Stable process
  2. Mapped processes
  3. Measurable processes

Item 3: How to 5S

  1. Total involvement of the entire group
  2. Take the time to do it right
  3. Follow up with pictures

Story: Implementation in a single-operator hobby workshop. Later videos on YouTube.

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In this episode, we will discuss Maintenance

Item 1: Scheduling Maintenance

  1. Cost Control
  2. Equipment maximization
  3. Capacity utilization

Item 2: Everyone Involved

  1. Getting buy-in
  2. Keeping buy-in
  3. I mean everyone is involved not just a few

Item 3: Customer satisfaction

  1. Customer feedback
  2. Customer engagement
  3. Customers need to know

Story: Implementation of Total Preventative Maintenance at a consulting client organization.

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In this episode, we will discuss How to employ Six Sigma

Item 1: Variation

  1. Process in control?
  2. Measurable
  3. Understood

Item 2: Define

  1. Justify why
  2. Assign who
  3. Gates with goals and controls

Item 3: Control

  1. Follow-ups
  2. Leadership clearly defined
  3. Communication well understood

Story: Starting a Six Sigma project just because….

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In this episode, we will discuss risk management

Item 1: Why manage risk

  1. Cost management
  2. Time Management
  3. People management

Item 2: When to manage risk

  1. Planning
  2. Development
  3. Execution

Item 3: How to manage risk

  1. Planning tools
  2. Development tools
  3. Execution tools

Story: Risk mitigation in the proposal to the customer

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In this episode, we will discuss Tool selection

Item 1: Define the whatever you are working on

  1. Size
  2. Time
  3. Cost

Item 2: Charter sets it up

  1. Limits
  2. People
  3. Communication types

Item 3: Breakdown

  1. Tool Types: Brainstorm, Just do, and complex
  2. Combo tools
  3. Matrix

Story: PFMEA to a DOE

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In this episode we will discuss Scope Control

Item 1: Establishment of scope

  1. Charter
  2. Work Breakdown Structure (WBS)
  3. Limitations and change control

Item 2: Creep

  1. Customer requirement creep
  2. No change controls
  3. People pleasing management (overcompensation)

Item 3: Kill it with fire

  1. Run on project
  2. The project is over but
  3. We start the project….Why?

Story: The Black Belt project that couldn’t.

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In this episode, we will discuss Management responsibility.

Item 1: Which part of Management is responsible for improvement

  1. Executive Management
  2. Middle Management
  3. Supervisory and Subject Matter Experts (SME)

Item 2: Large organization vs small business

  1. Roles of each management type
  2. Responsibilities differential by size
  3. Reporting and follow-up

Item 3: Belts and titles

  1. Green, Black, Yellow, Master and commander
  2. CEO to the supervisor
  3. SMEs

Story: Implementation at a small manufacturing company

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In this episode we will discuss statistics

Item 1: Is it really needed?

  1. Appropriate to the process
  2. Inspection type
  3. Data available

Item 2: Implementation

  1. Frequency of review
  2. KPIs
  3. Display of outputs

Item 3: Sustainment

  1. Goals
  2. Who sees the report?
  3. When to change?

Story: SPC implementation with a supplier as well as reporting on internal metrics.

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In this episode we will discuss process mapping

Item 1: Why

  1. Plan of PDCA
  2. Baseline current process
  3. Future state of process

Item 2: How

  1. Excel or Paper and pencil
  2. Visio
  3. PowerPoint

Item 3: When

  1. Beginning of a project
  2. Any process at all
  3. When developing a procedure

Story: Inclusion of process maps into procedures.

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In this episode we will discuss Lean Vs Sig Sigma

Item 1: Which is which

  1. Lean and Six Sigma implementation
  2. “ “              usage
  3. Execution of each

Item 2: Best of both

  1. 5s V 6S
  2. PDCA or DMAIC
  3. Design

Item 3: When not to use either

  1. Research and development
  2. Just fix it, damn it!
  3. Seriously it is a paperwork issue?

Story: Lean out a production line vs Six Sigma project to fix data through put issue.

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In this episode we will discuss project charters

Item 1: Why have them

  1. Defining the project
  2. Control Costs
  3. Effective allocation of resources

Item 2: How to use them

  1. Scope planning
  2. Cost planning
  3. Scheduling

Item 3: When to use them

  1. Any project
  2. Not for recurring tasks
  3. Must have an end built in

Story: When you ran a project without a charter and when you ran one with.

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In this episode we will discuss continual vs continuous improvement

Item 1: Why do it

  1. Competitive advantage
  2. Technology changes
  3. Cost savings

Item 2: Basics on how it is done

  1. TEAM WORK
  2. Customer focused
  3. Customer justified

Item 3: Sustain

  1. Set up accountability
  2. Ensure it is customer focused
  3. C level driven

Story: Implementation of process improvement in an anodize line and rejected motors.

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In this episode we will discuss how to get started in Manufacturing.

Item 1: Where to start

  1. Education
  2. Certification
  3. Experience

Item 2: Where to get the above

  1. School
  2. Intern
  3. Up from the production floor

Item 3: How to keep it up

  1. Continuing education
  2. Keep moving up in your organization
  3. Explore the industry

Story:

  1. Working as troubleshoot and repair
  2. MBA going nowhere
  3. Lean Six Sigma Black Belt Cert and beyond