Introduction to Lean Six Sigma Methods in the Aerospace Industry

Resources: Lecture Notes (PDF - 1.2 MB)

Learning Objectives
At the end of this module, you will be able to:
• Explain the origins of lean and six sigma
• Explain the “5S” lean tool
• Define Lean, lean enterprise and stakeholders
• Recognize why lean six sigma principles are being implemented in aerospace.
• Express that lean is a “journey” not a “state”

Presentation Contents:
• Key components which drive enterprise improvement
• Essential tools for business improvement
• Typical business improvement metrics
• Improvement as a process rather than an end state

Resources: Lecture Notes (PDF - 1 MB)

Learning Objectives

At the end of this module, you will be able to:

• Describe the elements of a process

• Draw a process map

• Explain what constitutes value in a process

• List the five fundamental lean principles

• Give a description several concepts and tools for implementing lean principles

Resources:
Lecture Notes (PDF)

S & A Hot Dogs: drawing a process map (PDF)

Learning Objectives:

At the end of this module, you will be able to:

• Sketch a basic value stream map

• Demonstrate basic value stream analysis

• Recognize steps for process improvement using value stream mapping and analysis

Resources: Lecture Notes (PDF)

Learning Objectives

At the end of this module, you will be able to:

• Name some lean terms, tools, and principles

• Summarize some enablers and barriers to implementing lean

• State the benefits of lean implementation at New Balance

Resources:
Lecture Notes (PDF)

Plant tour notes (PDF)

Overview

• Description of Lean Enterprise Simulation

• Use in Simulation-based learning

• Simulations as a CDIO practice field

• Evaluation of the simulation in the Lean Academy

• Caveats and Conclusions

Resources:
Paper (PDF), Presentation (PDF)

“Only 7% of companies today are effectively managing their supply chain. However, these companies are 73% more profitable than other manufacturers.”

Deloitte & Touche Study, October 2003

Learning Objectives

At the end of the module, you will be able to:

• Recognize the importance of suppliers in the enterprise

• Describe key attributes of a lean supply chain

1. Alignment of supply chain design with product characteristics

2. Supplier participation in material flow and logistics

3. Supplier involvement in design and development

4. Seamless information flow

• Discuss methods for the improvement of existing supply chains

Lecture Notes: (PDF)

Learning Objectives

At the end of this module, you will be able to:

• Explain how lean principles and practices apply to engineering

• Explain why customer value and the “front end” of engineering are critical to product success

• Describe how lean engineering enables lean in the enterprise and throughout the product lifecycle

• Describe tools for lean engineering

• Apply lean engineering techniques to redesign a simulated airplane

Resources:
Lecture Notes (PDF)

Learning Objectives

At the end of this module, you will be able to:

• Discuss the impact that variability has on process performance Learning About Variation

• In this module, we will gain understanding about impact of variation through two simulations

• Dice game will give experiential encounter

• Computer simulation will rapidly show impact of process changes

• We’ll discover a useful relationship between WIP, cycle time and takt time

• The quality module will introduce tools for variation and its impact on process capability

Resources:
Lecture Notes (PDF)

Variability simulation spreadsheet (XLS)

Instructions (PDF)

Learning Objectives

At the end of this module, you will be able to:

• Describe how quality is essential to lean in achieving Customer Satisfaction

• Explain the relationship between product quality and process quality control

• Use seven basic tools of quality

• Explain why Design for Six Sigma (DFSS) and Six Sigma are valuable concepts in achieving customer satisfaction

Resources:
Lecture Notes (PDF)

Learning Objectives

At the end of this module, you will be able to:

• Describe how quality is essential to lean in achieving Customer Satisfaction

• Explain the relationship between product quality and process quality control

• Use seven basic tools of quality

• Explain why Design for Six Sigma (DFSS) and Six Sigma are valuable concepts in achieving customer satisfaction

Resources:
Lecture Notes (PDF)

Resources: Ida Gall biography (PDF)

Learning Objectives

At the end of this module, you will be able to:

• Explain why people are the key to improving productivity

• Describe how to be an effective member of a team

• Compare & contrast leadership  vs. management

Resources:
Lecture Notes (PDF - 1.1 MB)

Individual values exercise (PDF)

Learning Objectives

At the end of this module, you will be able to:

• Describe important steps of implementing Lean principles and practices.

• List the barriers to implementation of Lean principles and practices

• Apply basic planning tools for implementing a Lean improvement project

Resources:
Lecture Notes (PDF)

Transition to Lean roadmap (PDF)