| Lean manufacturing combined with Six Sigma have | | | | case studies, exercises and examples. |
| been combined to form Lean Six Sigma. Both are | | | | The application of Lean Six Sigma in the US Army has |
| basically techniques to improve business. The concept | | | | resulted in reduction of expenditure and improvement |
| of Lean manufacturing comes from Toyota Production | | | | in productivity through contracting, manufacturing, |
| System while Six Sigma owes its origins to Motorola. | | | | administrative services and recruiting. |
| Both concepts when combined, can transform | | | | The Red river Army Depot at Texas in one such |
| organizations. | | | | example. The US Army was able to save $30 million |
| Elimination of waste and reduction in the time cycles | | | | on the production of Humvees. The unit upped its |
| are the goals of Lean while Six Sigma focuses on | | | | production from 3 Humvees a week in 2004 to a |
| improving quality and reducing variability. The goal of | | | | whopping 32 mission ready Humvees in a day by |
| any business is to maximize shareholder value. This | | | | 2006. |
| can be achieved by reduction in cost, increase in | | | | The Regional Readiness Command at Utah has been |
| quality, increase in process speed, a better return on | | | | able to reduce the cycle time from 90 to 21 days in |
| invested capital and improved customer | | | | awards processing. Previously, the deployment |
| satisfaction.When Lean Six Sigma is applied to | | | | preparation time for a battle-rostered unit was 30 |
| businesses, there are significant benefits in terms of | | | | days. On account of Lead Six Sigma this time period |
| improved lead time, reduction in costs and | | | | has been brought down to just 3 days! |
| enhancement of quality. | | | | LEADS, the system through which army starts the |
| The US Army has adapted the Lean Six Sigma to its | | | | recruitment process of prospectives, has improved |
| growing needs to eliminate waste in time, money and | | | | on account of Lead Six Sigma. The steps have been |
| material. To this end, the US Army Installation | | | | reduced from 32 to 11. This has brought down the time |
| Management Command or IMCOM for short has | | | | taken for the recruitment by 40%. |
| drawn up a training program for enhancing productivity | | | | The repair cycle time at the Pine Bluff Arsenal at |
| and reducing costs. | | | | Arkansan reduced by 90%. The production of M-40 |
| IMCOM has a training program for bringing about | | | | protective masks increased by 40%, on account of |
| transformation in the US Army through Lean Six | | | | Lean Six Sigma. |
| Sigma. The curriculum includes awareness and | | | | There was an $11.9 million reduction of cost in Patriot |
| conceptual training on how the concept of Lean Six | | | | air defense missile system recapitalization. |
| Sigma fits into the overall strategy of the US Army to | | | | At the Corpus Christi Army Depot in Texas, the time |
| make it efficient and productive. Hands-on | | | | taken to rebuild the UH-60 Blackhawk decreased from |
| understanding of the process is given; participants are | | | | 256 days to around 70. |
| imparted knowledge on how to identify projects and | | | | In the backdrop of fiscal constraints that the US Army |
| select them for the purpose of applying Lean Six | | | | is facing, these cost savings have come in as a |
| Sigma. The roles and responsibilities of a Leader are | | | | morale booster. While, undoubtedly there have been a |
| highlighted. The curriculum also includes training in tools | | | | number of examples of costs savings and |
| and skills necessary for effective and efficient | | | | improvement in productivity on account of |
| implementation of Lean Six Sigma. | | | | implementation of Lean Six Sigma, more profound has |
| Personnel have divided into Green Belts and Black | | | | been the impact of the common US soldier. Despite |
| Belts. Green Belts are taught to be effective team | | | | the initial resistance, wherever it has been implemented |
| members. They are taught the DMAIC concept of six | | | | in the US army, it has met with success. |
| Sigma. DMAIC is the acronym for, Measure, Analyze, | | | | Peter Peterka is the President of SixSigma.us. For |
| Improve and Control.Black Belts are those who will use | | | | information on Six Sigma, Six Sigma Certification or |
| the processes and tools required to implement DMAIC | | | | Online Six Sigma programs contact Peter Peterka. |
| methodology. Black Belts are taught through simulation, | | | | |