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HowtouseLeanSixSigmatoimprovecorporationprocess-Learn“LeanSixSigmaOverview”andpracticeinrealoperationIntroduction:ZhangDong:LeanSixSigmaManageratIngersollRand,DeputypresidentofLeansixsigmacommittee,ChiefeditorofAsiaLeansixsigmaweeklymagazine,Chinaqualityassociationsixsigmapromotioncommitteemember,authoroffromstrategictoexecute—Leansixsigmamanagementpractice,ShededicatetopromoteLeanSixSigmamethodinrealworldandservestoteachasHonoraryProfessorinShanghaiJiaotongUniversity,AntaiCollegeofEconomicandManagement.WilliamLiang:ShanghaiJiaotongUniversityAntaiCollegeofEconomicandManagement,ChinaLeadersformanufacturingProgramme.AfterreceivedB.E.degreeofMaterialPhysicsfromCentralSouthUniversityin2004,heservedinLairdtechnologyandSaintGolban.Hedevotestoleansystembuildingandleanimplementincorporation.Asstudent,WilliamLiangstudiesLeanSixSigmainZhangDong’scourse.Forward:On19thDec,2010wewarmlywelcomeMsZhangDongtobringavividlecturecombinedwithhermanyyearsaccumulatedconsultingexperienceandresearchachivement.ThelectureopenedfromcoreconceptofDMAICL,whichmeans“define,measure,analysis,improve,controlandleverage”,acreativeconceptdevelopedtraditionalDMAICmethodand6sigmatoolsthatinitialfromMotorola,GEtoamodernbroadlyimplemented6sigmaconceptnotonlyusedinmanufacturingindustrialbutalsoinserviceindustialsuchasgreatlogisticscircle(SIPOC),fromsuppliers,producer,wholesalertodistributor.Thelecturerbroughtanewlydevelopedconceptfortoday’sevolutionarycooperationmodelinindustrialchainanddevotetowidelyleveragethisadvancedconceptandtheorytopromotecompetenceofindividualcompaniesaswellasnetworkinwhollyindustrialchain.Afterabsorbthisconcept,Icombinedmyworkcontenttostudyhowtoapply6sigmaandDMAICLstepstoimproveoureffectivenessincorporateoperation.Text:Withthelivingstandardrisingdramatically,automobileconsumptionkeepincreasingandhasbeenwitnessedtobecomethelargestmarketglobally.In2010,domesticsalesvolumereached18,060,000,withacceleration32%.Weconfidentlyforecastthatthisrisingtrendwillholdformanyyears.Engineproductionandsalesbenefitfromthistrendanddomesticmanufacturingadvantage,withprofitrateover20%,even40%insomecorefirms.Asvehiclepartsmanufacturingisacapitalandlaborintensiveindustry,contributehighweighttoregioneconomic,itismeaningfultoresearchhowtopromoteprocesscapabilityandproductivityinthisindustry.LeansixsigmamethodcombineleanandsixsigmaanddevelopedtraditionalLeanorSixsigmamethod,bringingnewopportunityforenhancingcorporationprocess,acceleratingdelivery,turnoverwhileeliminatewastewithinprocessorfirms.Thefirmsthatadoptthisadvancedmethodperformhighestprofitabilityandcompetitivenessinmarket.Chart1.1ChinaandU.S.Automobileandvehicleconsumptiontrendamong2007~2010Chart1.2Chinaautomobilemarkettrendofvariouskindsfrom2003to2010.Chart1.3DomesticautomobilesalestrendindecadeforLarge,big,medium,smallandminitype.Raiseourplantforexample,wedailyproduceandassemblethousandsofengineswhichbroadlyusedinvariousvehicles,saletotop6automobileOEMs,includingdomesticandjointventurefirms.Qualityandontimedeliveryisvitalforengineplantaswellasforourclient.Chart2:SIPOCflowchartofourplant.Fromthechartmentionedabove,weknowthatSupplier,ourplantandclientsformalink,andamongupstreamanddownstreamthereexistmanysimilarlinks.Theselinksformachain,whichcanalsobecalledcircle,andturnoverrate,inventoryvolume/valuebesetasbenchmark.Meanwhile,accompaniedwithmaterialflow,informationflowandcashflow(orcapitalflow)formthewholevalueflowsystemamongthechains,involveinternalandexternaldepartmentsforenginemarketingandsales,orderacceptance,design,suppliercontracting,productionandassembly,product&servicedelivery,financesettlement.Aluminumingot,andassembliessupplierOurplantAutomobile&vehicleproducerDistributor(4Sstore)InputOutputSIPOCTobeleverage...Amongtheprocessweaddvaluetorawmaterialresourcethatweprocuredfromupstreamanddeliverthisvaluetocustomer.Theinformationflowmovingbackwardfromdownstreamtoupstream,includingcustomerrequirement,marketforcast,rejectionorrework,etc.Hereweraiseaproductlineasanexampletoexplainourprocessimprovement.——CylindeChart3.1VSM(valuestreammap)forCylindeprocessbeforeimprovementAfteridentifyvalueaddedstepsandvalueaddedtimeineachsteps,wefindoutnon-valueaddedtimeinstepsrespectively.Furtherimprovementmeasuresbasedontheseidentificationandanalysis.Eg,wereducedcastingsetuptimefrom40hto24hbykeepingmeltingfurnace’stemperatureandcastingmachinepreparation.Intheseway,wedramaticallyreducetimewaste.Owingtoleadtimereduction,wecanquicklyresponsetocustomerorderandreduceinventory.TheseeffortcontributetotensofthousandsRMBpermonthforeachproduct.机械加工流程.igxFinalassemblyplantMelting总C/T=90分钟增值:32分钟非增值=58分钟缺陷=2%package总C/T=3.01小时增值:60秒非增值=3小时productionmaterialplansupplierinfoorder/planorder/planinfo客户需求：每月为8000件（节拍时间567秒）inventorywarehouse40 小时3 分钟4.5 分钟20 小时19 分钟4.32 小时50 小时300 分钟9 小时1.5 分钟29 分钟3 小时4.8 分钟5.05 分钟1 分钟3.02 小时8 小时前导时间=138小时增值时间=329分钟原料=0秒在制品=130小时成品=8小时已移动=0米移动工作平衡0分钟4.69分钟262分钟540分钟29分钟5.05分钟181分钟节拍时间96分钟gravitycasting总C/T=4.5分钟增值:3分钟非增值=90秒缺陷=4%pretreatment增值:19分钟非增值=4小时缺陷=1%heattreatment总C/T=9小时增值: