McKinsey---Six Sigma& Lean.ppt
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1、McKinsey-Six Sigma& Lean030602MVA_he_ZZT_7861GE has become the poster child of the Six Sigma movement 43216810152235501987 889092949596989901 2002Cumulative Fortune 500 program launchesEstimatesEra 1 (1987) QualityEra 2 (1994) Financial performanceEra 3 (1996) Performance Improvement Umbrella Era 4
2、(2000) Strategic issuesWhy did GE adopt Six Sigma?Intense pressure on margins and no room for price increases premium on productivityMediocre quality and disappointed customersBillions of dollars lost in cost of poor qualityReenergize GEs productivity machineEngine for cultural transformationEvoluti
3、on of Six SigmaGESource: McKinsey030602MVA_he_ZZT_7862Delivery exampleSix Sigma has its roots in statistical process controlBeforeAverage delivery time: 45 minutes55 minutes(Commitment to customer)Before: 2 (i.e., 30.85% delivered outside target times)After: 6 (i.e., only 0.0003% delivered outside t
4、arget times)35 minutesSource: McKinseyCritical-to-quality metric: on-time delivery7 articles lost per hour1.7 incorrect operations per week1 short or long landing every 5 years68 wrong prescriptions per year99.99966% Good (6 Sigma)99% Good (3.8 Sigma)Other process capability examples20,000 lost arti
5、cles of mail per hour5,000 incorrect surgical operations per week2 short or long landings at most major airports each day200,000 wrong drug prescriptions each yearAfter20,000 lost articles of mail per hour5,000 incorrect surgical operations per week2 short or long landings at most major airports eac
6、h day200,000 wrong drug prescriptions each year030602MVA_he_ZZT_7863The Six Sigma program has three key elementsBrainstormingAffinity diagramsMulti-votingHypothesis testingPareto chartsFishboneProcess mappingRoot cause problem solvingMaster Black Belts(full time)Support key line executivesResponsibl
7、e for project selection, training/coaching of Black Belts and reporting progressBlack Belts(full time)Lead improvement projects through DMAIC cycleReceive 4 weeks of up-front trainingGreen belts(part time)Provide Black Belts with support to get projects doneReceive less intensive trainingStatistical
8、ly-focused problem solving toolsDedicated and certified resources3.Focuses on reduction in variation of key metrics2.Drives measurement and data-driven analysis of metrics that are critical to customers1.Creates standardized, disciplined problem solving approach used across companyAll Six Sigma impr
9、ovement efforts optimize processes by reducing variationDefine the problemMeasure the problemDefineMeasureAnalyzeImproveControl Analyze and identify the gapIdentify and implement solutionsTrack and review progressDMAICPrescriptive Problem Solving Process DMAICDesign of experimentVoice of the custome
10、rQuality function deploymentANOVAEtc.030602MVA_he_ZZT_7864Improvement infrastructure GEs Six Sigma success is based on a thoughtful understanding of the drivers of large-scale change1243Set aspirationsArchitect programImplement changeBuild momentumEffective, well-orchestrated launchTrain top leaders
11、 and set aspirationsArchitect program and begin massive communication drive Select and deploy high-potential resourcesExecute high profile projects and make teams heroesRelentlessly communicate successes and changes to comeGE used several core elements of successful transformation programsOrganizati
12、onal enablersLeadership Intense involvement of top and line leadershipProgram designRobust roadmap and processesPerformance management Goals baked into budgets at all levels Dedicated resourcesBest resources with clear career pathsTalent/skill development Multi-level training Program supportRuthless
13、 project manage-mentProblem solving Disciplined use of DMAIC and tools199619961996 - 971997Source: McKinsey030602MVA_he_ZZT_7865Six Sigma projects follow a disciplined approach to root-cause problem solving Clearly definethe problem, the goal, and the processBaseline and further refine the problem A
14、nalyze to identify the vital few root causes Select solu-tions; test on pilot; imple-ment full scale Control the process to sustain gains Define Measure Analyze Improve Control What is the problem?Goal?Customers?Process to improve?What is the ex-tent of the pro-blem? Efficiency EffectivenessWhat dat
15、a do we need to get to the root causes?Range of optionsSolutionsBest pragmatic solutions Full range of solutionsThe select fewThe optimal and pragmatic solu-tionSmall scale pilotFull scale implementationTactical level Process standardization Process through-putStrategic level Disciplined use of busi
16、ness pro-cess manage-ment by steering committeeKey elementsDeliver-ablesClarity on what is in scope and what is out of scopeIn-depth under-standing of how big the problem is and data to get to the bottom of itData driven rigorous con-clusions on the vital root causes for the problemFully imple-mente
17、d solu-tion based on lessons from pilotStable processSystem to keep it stableFully integrated into business goalsExecutives fully involved Source: McKinseyDMAIC 030602MVA_he_ZZT_7866Six Sigma has had high impact on service businesses Problem definitionReduce accounts receivables tobest-practice leve
18、ls in 24 weeks Organizational enablers and improvement infrastructureCFO sponsor with division heads present at project launchCFO and division heads attend key status reviewsBlack Belt coach and guide but led by finance managerProject tracked by Six Sigma staff and through steering committee meeting
19、sProblem solving methodologyand toolsDMAICTools used on project brain-storming, fishbone, pareto, histo-grams, scatter plots, check sheets, control charts is-is not, force field analysis, simple FMEA, poke-yokeResultsReduced AR by 90% for annual benefits exceeding USD 4 millionSample tools used Fish
20、bone defective invoice ManMeasure-mentMachine MethodMaterialEnvironmentDefective invoiceTraining Metrics No check against POPareto RecommendationsControl chartPOT&CDeli-veryOtherImprove invoice quality by following actions Mandatory check of PO against invoice 5-day training of personnel by experien
21、ced gurus with best practices One invoice per PO with itemized list of all itemsImplement segment based control system for customers. Set target goal into annual MBO to ensure accountability Set guidelines for action, red, yellow, green flags for escalating actions Observe strict $ penalties for lat
22、e payment Monitore control chart of key metrics Days(USD delin-quency days) = USD invoice x days lateUpper control limitUpper spec. limitLower spec. limitLower control limit Special causesSource: McKinseyPROJECT REDUCE DELINQUENT ACCOUNTS RECEIVABLES 030602MVA_he_ZZT_7867Green beltBlack beltExecutiv
23、e sponsor/division managerPart-time-position leading Six Sigma. Continues fulfilling current job responsibilities Trained in Six Sigma tools, provides functional/ divisional knowledge and expertiseMentored by a black belt Communicates Six Sigma methodology to others in the organizationFull-time dedi
24、cation to Six Sigma; Leads projects and shares responsibility for deliverablesApplies right Six Sigma methodology and tools to ensure quality of process Escalate issues to managementTrains and coaches team membersProposes Six Sigma improvement projects and responsible for deliverablesResolves issues
25、 Promotes Six Sigma strategy and methodologyUnderstands Six Sigma strategy, discipline and toolsSix Sigma roles Source: McKinsey030602MVA_he_ZZT_7868Although the impact from Six Sigma has been significant for GE .00.40.81.21.619969798992000Percent of salesSix Sigma net financial impact*USD mGE total
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