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itm@itmconsulting.com

Board Talk

SIX-SIGMA Lite (CIPQ) and LEAN Lite (Lean Manufacturing)

In today's difficult times, quality and profitability have never been so important and so challenging.

Yet, it surprises many people to find that very small improvements in productivity can result in exponential improvements in profit.

Here is an example. Let's say you were losing just 3 minutes per shift each day. Maybe you waited a little to replenish the solder paste, or dallied some when you went to get the stencil for the new job. No big deal right?

Wrong! Depending on your line the results will vary, but on the average line you would lose $90K of production per year. Remember, the only profits you generate are from the products coming off the end of your lines!

ITM would like to audit your line for such time wasters and also search for process, material, and equipment problems and improvements, all of which will directly impact the quality of your products and productivity of your operations.

We would also like to cost model your facility with ProfitPro3. This cost model will help us to predict the profit improvements possible with our recommended productivity enhancements.

SIX-SIGMA Lite: Continuous Improvement Plan for Quality (CIPQ)

Course Description:

CIPQ, presented by ITM Consulting, is a 2 day intensive practical course designed to provide a plan for a continuous improvement program for quality for Electronic Manufacturing and to facilitate such initial improvement programs within the organization. It is targeted at leaders who can appreciate the benefits of significant improvements in quality throughout their organizations who are already interested in utilizing and improving their existing quality data and are considering using CIP tools such as SPC and Pareto as a foundation to make continuous improvements in their company’s operations.

Topics Covered

Continuous Improvement Concepts

Developing & Evaluating Test and Inspection Techniques and Strategies (Gauge R&R)

·Statistical Process Control

· Pareto Analysis

· Implementation at the facility

· Designation of a CIPQ Champion

This program is designed to allow leaders (managers, CEO’s, etc) to understand some of the basic principles and practical benefits of a Continuous Improvement Plan for Quality and it provides simple but effective tools to support successful implementation of real money saving (waste eliminating) projects. Specific tools for improving quality will include test & measurement strategies, statistical process control, and Pareto analysis. To facilitate the understanding of these techniques, examples will be presented from SMT assembly that can be related to the student’s daily job. The student will learn how to establish and implement a statistical process control program and use Pareto analysis all in the framework of a continuous improvement program. As part of the training, students will work through a small project of their own choosing within their own working environment, and complete the program by developing an expanded outline of future improvement projects, including Metrics, Action Items, and Personnel Assignments. ITM Staff will offer follow-up assistance on evaluating the implementation of these projects.

Teamwork is one of the foundations of CIPQ and will be emphasized and developed throughout the course in class exercises and project activities. This course will facilitate the empowerment of all employees, moving involvement and decision making to the lowest appropriate level. This has been found to be extremely helpful in developing a personnel and improving management structure; especially for small and medium-sized organization which are expanding their operations and work force.

Having taken the course and undertaken one or more projects, leaders will be motivated, including practical justifications for investments in time and training, to become Champions to expand the deployment of CIPQ techniques throughout their organizations, ultimately creating a comprehensive company-wide Continuous Improvement Program for Quality.

The course consists of 2 full days, onsite at your facility and includes a combination of lectures, classroom examples, and practical exercises based on your own operations.

Presented by ITM Consulting and taught by two LSS Master Black Belts from the Dartmouth College LSS program.

Course Title: Six-Sigma Lite: Continuous Improvement Plan for Quality (CIPQ)

Instructors: Dr. Ron Lasky and Jim Hall, Lean Six-Sigma Master Bl

Duration: 2 Days

Course Outline

1. Classroom: lectures & exercises

a. Introduction to Continuous Improvement for Quality

i. Fundamentals of Continuous Improvement Programs

ii. Team Concepts

iii. 6-sigma concepts

1. Use and value of DOE

iv. Outline of DMAIC problem solving structure

v. Success stories

vi. Sustainability for Continuous Improvement

b. Test & Measurement Development

i. Test & Measurement Techniques

ii. Accuracy

iii. Sampling

iv. Evaluations: Gauge R&R

c. SPC: Statistical Process Control

i. Special and Common Cause Variation

ii. Precision and Accuracy

iii. Shewhart Rules

iv. SPC Charting with Minitab

v. Cp and Cpk

vi. Minitab Capability Six Pack

d. Pareto Analysis

i. How Pareto Analysis works in CIPQ

2. Introductory in-plant project

a. Student walk through w/ coaching

b. Project definition

c. Project execution: improvements, measurement plan, (specifics will depend on project chosen by students)

3. In-Plant macro CIPQ evaluation

a. In-Plant observations & coaching

b. Summarize & organize observation

c. Brainstorm possible projects / improvements

d. Develop deployment plan

After completion of the 2-day course

4. Follow-up with ITM Instructors

a. Project progress

b. Fine-tuning and modifications

c. Additional training requirements

Who Should Attend

  • Managers concerned with the status quo and interested in investigating options for productivity improvement, performance enhancement and organizational change.
  • Leaders considering embarking on a quality improvement strategy and are in a position to become Champions of implementation and deployment.
  • Key employees from all departments within the organization to understand the methodology that their company is embarking on and the potential benefits it can offer.

LEAN Lite

Course Description:

LEAN Lite, presented by ITM Consulting, is a 2 day intensive practical course designed to provide an introduction and basic skills in LEAN 6-Sigma (LSS) implementation for Electronic Manufacturing and to facilitate initial improvement programs within the organization . It is targeted at leaders who can appreciate the benefits of significant improvements in efficiency and quality throughout their organizations and are considering using LEAN 6-Sigma as a system to make continuous improvements in their company’s operations.

This program is designed to allow leaders (managers, CEO’s, etc) to understand some of the basic principles and practical benefits of LEAN and it provides simple but effective tools to support successful implementation of real money saving (waste eliminating) projects. Specific tools for improving productivity will include Line Balancing and evaluations of Down-Time in automated assembly operations. To facilitate estimating financial benefits of potential improvement projects, a simple, spreadsheet based Cost Model of the manufacturing facility will be developed during the course. As part of the training, students will work through a small project of their own choosing within their own working environment, and complete the program by developing an expanded outline of future improvement projects, including Metrics, Action Items, and personnel assignments. ITM Staff will offer follow-up assistance on evaluating the implementation of these projects.

Teamwork is one of the foundations of LSS and will be emphasized and developed throughout the course in class exercises and project activities. This course will facilitate the empowerment of all employees, moving involvement and decision making to the lowest appropriate level. This has been found to be extremely helpful in developing a personnel and improving management structure; especially for small and medium-sized organization which are expanding their operations and work force.

Having taken the course and undertaken one or more projects, leaders will be motivated, including practical justifications for investments in time and training, to become Champions to expand the deployment of LEAN 6-Sigma techniques throughout their organizations, ultimately creating a comprehensive company-wide LSS Continuous Improvement Program.

The course consists of 2 full days, onsite at your facility and includes a combination of lectures, classroom examples, and practical exercises based on your own operations.

Presented by ITM Consulting and taught by two LSS Master Black Belts from the Dartmouth College LSS program.

Course Instructors: Dr. Ron Lasky, Jim Hall

Duration: 2 days

Course Outline

  • PART I: Classroom: lectures & exercises
    • Introduction to LEAN 6-Sigma
      • Fundamentals of Continuous Improvement Programs
      • Team Concepts
      • 6-sigma concepts
      • Outline of DMAIC problem solving structure
      • Success stories of LSS implementation
      • Sustainability for Continuous Improvement
    • Simple LEAN Tools
      • The 7 MUDA’S (Wastes)
      • 5-S
      • Flow Charts
      • Layout Maps
      • Attribute (counting) Data => PARETO charts
      • SIPOC map (Suppliers, Inputs, Processes, Outputs, Customers)
    • 6 Sigma very lite (SPC, Cp & Cpk, DOE example)
    • Sustainability
  • PART 2: Introductory in-plant project
    • Student walk through w/ coaching
    • Project definition
    • Project execution: improvements, measurement plan, (specifics will depend on project chosen by students)
  • PART 3: In-Plant macro LSS evaluation
    • In-Plant observations & coaching
    • Summarize & organize observation
    • Brainstorm possible projects / improvements
    • Develop deployment plan
  • PART 4: After completion of the 2-day course
    Follow-up with ITM Instructors
    • Project progress
    • Fine-tuning and modifications
    • Additional training requirements

Who Should Attend

  • Managers concerned with the status quo and interested in investigating options for productivity improvement, performance enhancement and organizational change.
  • Leaders considering embarking on a Lean and/or Six Sigma strategy and are in a position to become Champions of implementation and deployment.
  • Key employees from all departments within the organization to understand the methodology that their company is embarking on and the potential benefits it can offer.