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how many people needs a Lean-SixSigma deparment?

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  • #42153

    Cordoba
    Participant

    Hi every one , I’m Lean-Sixsigma Manager , and i’m initiating the Lean-Sixsigma deployment in a Automotive plant of 900 employees, I’ll like to know (based in your knowleged and experience) -How many people at my department? I’ll need in order to develop the deployment and the implementation…..

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    #132934

    Mikel
    Member

    4.5

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    #132937

    Mike Carnell
    Participant

    Alejandro,
    There are more factors that affect it than just the number of people you have in your facility.
    The standard answer is 1% or 9. Stan is probably closer at 4-5. if you run on straight percentages and everyone is in one location.
    How well will your 900 people handle 20 – 25 changes over the next 12 months? How well will they handle 45? An easier question – will your process owners identify and support 20 – 25 projects in the facility over the next 12 months?
    You are better off with a strong GB program and a minimal nuber of BB’s.
    Just my opinion.
    Good luck

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    #132940

    Dr. Scott
    Participant

    Alejandro,
    I agree with both Stan and Mike. Mikes 1% rule is an industry standard. That is likely the most you will need. However, starting out with 4-5 is likely the best approach in the beginning until you can, as Mike suggests you should, develop Green Belts and the ability to work across all processes in the facility. You will likely want to consider an MBB as well.
    Just my two cents,
    Dr. Scott

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    #132943

    Schuette
    Participant

    Umm, Mike and Dr. S – Stan said 4.5, not 4-5.
    Clearly he was taking into account the 1.5 shift, so rather than the standard 6 +/- 1.5, Stan is incouraging her to be Lean by using the optomistic side of the 1.5 shift.

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    #132952

    AB
    Participant

    Alejandro
    I would recommend you start differently. List all potential project opportunities (likely you have a list that was used to create the business case for initiating your deployment). Then look at the ROI, organizational capacity for change and prioritize. Try and lay these projects out on a calendar. Say, you end up having 8 projects in the first year, each spanning 4-6 months and 12 projects for next year. Now you know that you need at least 4, maybe 5 project leaders. GB/BB? Depends on what they bring to the table.
    It’ll probably get you to the same answer that Mike, Stan and Scott have provided but now you will know why you need them.
    Good luck
    AB
     

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    #133442

    Allison
    Participant

    Alejandro,
    If you are not a Master Blackbelt, I would suggest you start by hiring an experienced MBB. Rule of thumb in our company is one MBB in each plant, one BB for 100-125 employees and 20% of the employees as GB. We also give Champion training to all departmental managers. This makes a big difference for ongoing support. Keep in mind, anybody who will be working on implementing 5S, standard work etc may not have any time to work full time on 6S projects. Don’t forget, all the BBs will be spending time on mentoring the greenbelts as well. At least this is my experience. Good luck.

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