Marine Depot Maintenance Command started by implementing the following Lean concepts.
General clean up of the entire center and institutionalize daily/weekly clean ups
Removal of excess parts from the shop floor
Improved tool inventory and control
Implemented the 6S Concept
Lean 6S Concept
Safety: Address and correct any safety issues
ALWAYS put Safety first!
Sort: Separate everything based on usage and discard
Straighten: Organize everything and label accordingly– A place for everything; everything in its place
Scrub: Clean everything (Equipment, Floors, and Walls)
Standardize: Maintain guidelines, assign tasks, and create procedures
Sustain: Audit and inspections based on checklist
Lean Six Sigma
Marine Depot Maintenance Command (MDMC) is further developing its implementation of Lean Six Sigma (LSS). The MDMC has being using various Lean techniques since 2002, and the Marine Depot Maintenance Command wants to develop its LSS program and use it to continually improve it processes.
Concepts of Lean
Goal is to accelerate the speed of any process by reducing all forms of waste
Focuses on process speed/velocity
Provides tools for analyzing process flow and delay times at each activity
Focuses on separating "value added" and "non value added" work
Provides tools to eliminate the causes of "non value added" work
Provides methods to measure process complexity and methods to simplify it
If we are doing something because “it’s just the way we do things” then it is probably waste
Examples of waste or “non value added” work: defects, inventory, overproduction, wait time, motion, transportation, and processing waste.
Concepts Six Sigma
Recognize opportunities and eliminate defects as defined by the customer
Variation should be reduced since it hinders our ability to meet cost, schedule, and quality requirements
Decisions should be made based on data
Includes a set of quality tools to solve problems and analyze data
Provides a structured manor that helps aid in getting results
A Six Sigma quality level means there is less than 3.4 defects per million opportunities
Levels of Lean Six Sigma Training/Certification:
Black Belt – Leads major problem solving projects and is fully trained/experienced on all Lean Six Sigma techniques. Trains and coaches green belts and other team members.
Green Belt – Leads small problem solving projects. They also assist with data collection and analysis for Black Belt Projects.
Master Black Belt - Trains and coaches Black Belts and Green Belts.
Champions: Helps facilitate the implementation of Lean Six Sigma and identifies projects. Identifies resources for the projects and removes roadblocks.