Lean Six Sigma in 8 Minutes. What is Lean Six Sigma? Process Improvement.

Lean Techniques Explained (based on Process Analysis)

Lean is a systematic method for increasing efficiency by reducing waste and maximizing value. Lean principles, which originated with the Toyota Production System, are now widely employed in manufacturing, healthcare, logistics, and the service industry. Here are the main Lean techniques: See below.

Lean strategies emphasize waste elimination, workflow improvement, and continual process optimization. Companies that use Lean can increase productivity, lower costs, and improve product quality while providing better value to customers.

Six Sigma Techniques (based Data Statistics)

Six Sigma is a methodology established by Bill Smith of Motorola in the 1980s to find inefficiencies, decrease errors, and optimize processes. The goal of this technique is to eliminate process variability and faults, with a success rate of 99.9996% and only 3.4 errors per million opportunities. It enhances product quality, customer happiness, employee morale, and productivity.

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Highly recommended video by Simplilear to understand both concepts:

• YouTube Video: https://youtu.be/s2HCrhNVfak?si=hbAFsO9ZxJL6hWWi

1. The 5 Principles of Lean

Lean operates on five core principles:

1. Identify Value – Understand what customers value and focus on delivering it.
2. Map the Value Stream – Analyze the entire process to identify waste.
3. Create Flow – Ensure a smooth and uninterrupted workflow.
4. Establish Pull – Produce only what is needed when it's needed.
5. Seek Perfection – Continuously improve processes to reduce waste and inefficiency.

***Lean Methodologies/Techniques***

2. Lean Techniques and Tools

a) 5S Methodology – Organizing the Workplace

A structured approach to workplace organization that improves efficiency and safety:

1. Sort (Seiri) – Remove unnecessary items.
2. Set in Order (Seiton) – Arrange tools and materials for easy access.
3. Shine (Seiso) – Keep the workspace clean and maintained.
4. Standardize (Seiketsu) – Create standardized processes.
5. Sustain (Shitsuke) – Maintain discipline and continuous improvement.

b) Lean Techniques and Tools

Value Stream Mapping (VSM) – Process Optimization

A visual tool used to map out the entire process, identifying waste and areas for improvement.

Kaizen (Continuous Improvement)

A mindset and practice focused on small, incremental improvements in processes, led by employees at all levels.

Just-In-Time (JIT) Production

Producing exactly what is needed, when it is needed, in the amount needed, to minimize inventory waste.

Kanban (Visual Management System)

A pull-based system that uses visual signals (cards, boards) to manage workflow and production.

Poka-Yoke (Error Proofing)

Implementing mechanisms that prevent mistakes before they happen, such as design features that prevent incorrect assembly.

Standardized Work

Establishing best practices and standard operating procedures (SOPs) to maintain consistency and efficiency.

Heijunka (Production Leveling)

Balancing production to avoid bottlenecks and ensure a steady workflow.

Total Productive Maintenance (TPM)

A proactive approach to maintenance that reduces downtime and maximizes equipment efficiency.

Gemba Walks

Managers physically visit the workplace to observe and understand processes, gather insights, and encourage employee engagement in problem-solving.

***Six Sigma Methodologies/Techniques***

DMAIC Methodology – Used to improve existing processes, DMAIC stands for Define, Measure, Analyze, Improve, and Control.

• Define – Identify problems, customer needs, and improvement opportunities.
• Measure – Assess current process performance using key metrics.
• Analyze – Identify root causes of defects and inefficiencies.
• Improve – Implement process improvements and optimize workflow.
• Control – Maintain improvements through regular monitoring.

DMADV Methodology – Used for new product development, DMADV stands for Define, Measure, Analyze, Design, and Verify.

• Define – Determine customer needs and product specifications.
• Measure – Establish measurable specifications for the new product.
• Analyze – Evaluate design alternatives and identify improvements.
• Design – Create and refine the product based on findings.
• Verify – Test the final product against customer expectations.

This image represents a normal distribution (bell curve) commonly used in statistical process control (SPC) and Six Sigma methodologies. It illustrates how data points are distributed around the process average (mean) and within standard deviations (σ).

Here's a breakdown:

Mean (Process Average): The center of the distribution.

Standard Deviations (σ):

• 68% of the data falls within ±1σ.
• 95% falls within ±2σ.
• 99.7% falls within ±3σ (though not explicitly shown in the image).

Control Limits:

• The lower limit and upper limit are set at ±6σ, indicating Six Sigma quality standards.
• Any data points beyond these limits are considered defects or out-of-specification.