operations

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• SKILL.md
• operations-excellence-skill.md · references/

SKILL.md (first lines)

# Operations Expert

Comprehensive operations frameworks for process improvement, supply chain management, and operational excellence.

## Operational Excellence Frameworks

### Lean Manufacturing Principles

```
THE 5 PRINCIPLES OF LEAN:
1. Value - Define from customer perspective
2. Value Stream - Map all steps, eliminate waste
3. Flow - Make value-creating steps flow smoothly
4. Pull - Let customer demand drive production
5. Perfection - Continuously improve toward perfection
```

### 8 Wastes (DOWNTIME)

| Waste                   | Definition                        | Examples                           | Countermeasures                   |
| ----------------------- | --------------------------------- | ---------------------------------- | --------------------------------- |
| **D**efects             | Work requiring rework/scrap       | Quality issues, errors             | Poka-yoke, quality at source      |
| **O**verproduction      | Making more than needed           | Excess inventory, WIP              | Pull systems, kanban              |
| **W**aiting             | Idle time between processes       | Queue time, approvals              | Flow optimization, cross-training |
| **N**on-utilized talent | Underusing employee skills        | Manual data entry, routine tasks   | Empowerment, automation           |
| **T**ransportation      | Unnecessary movement of materials | Multiple handling, poor layout     | Facility layout optimization      |
| **I**nventory           | Excess stock/materials            | Safety stock, WIP                  | JIT, demand planning              |
| **M**otion              | Unnecessary worker movement       | Poor workstation design            | 5S, ergonomics                    |
| **E**xtra processing    | More work than required           | Over-engineering, redundant checks | Value stream mapping              |

### Six Sigma DMAIC

```
DEFINE
- Problem statement
- Project charter
- Voice of customer (VOC)
- SIPOC diagram
- CTQ (Critical to Quality) tree

MEASURE
- Data collection plan
- Process capability (Cp, Cpk)
- Measurement system analysis
- Baseline metrics

ANALYZE
- Root cause analysis (5 Whys, Fishbone)
- Statistical analysis
- Process mapping
- Hypothesis testing

IMPROVE
- Solution generation
- Pilot testing
- Implementation plan
- Risk assessment (FMEA)

CONTROL
- Control plan
- Statistical process control (SPC)
- Standard operating procedures
- Training and handoff
```

### Six Sigma Metrics

| Sigma Level | DPMO    | Yield    |
| ----------- | ------- | -------- |
| 1           | 691,462 | 30.9%    |
| 2           | 308,538 | 69.1%    |
| 3           | 66,807  | 93.3%    |
| 4           | 6,210   | 99.4%    |
| 5           | 233     | 99.98%   |
| 6           | 3.4     | 99.9997% |

## Supply Chain Management

### Supply Chain Strategy

| Strategy         | When to Use                               | Key Characteristics                           |
| ---------------- | ----------------------------------------- | --------------------------------------------- |
| **Efficient**    | Stable demand, commodity products         | Low cost, high utilization, minimal inventory |
| **Responsive**   | Unpredictable demand, innovative products | Speed, flexibility, buffer inventory          |
| **Risk-Hedging** | Supply uncertainty                        | Multiple suppliers, pooled inventory          |
| **Agile**        | Demand and supply uncertainty             | All above combined, modular design            |

### SCOR Model (Supply Chain Operations Reference)

```
PLAN
- Demand planning
- Supply planning
- S&OP process
- Inventory planning

SOURCE
- Supplier selection
- Contract negotiation
- Procurement
- Supplier performance

MAKE
- Production scheduling
- Manufacturing execution
- Quality management
- Capacity management

DELIVER
- Order management
- Warehousing
- Transportation
- Last-mile delivery

RETURN
- Reverse logistics
- Returns processing
- Warranty management
- Disposal/recycling

From travisjneuman/.claude, MIT.

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