Lean Six Sigma

  1. The Lean Framework
    1. Core Lean Principles
      1. Defining Value from Customer Perspective
        1. Identifying Value-Added Activities
          1. Understanding Customer Requirements
            1. Value Definition Process
            2. Mapping the Value Stream
              1. Identifying Process Steps
                1. Distinguishing Value-Added vs. Non-Value-Added Steps
                  1. Information Flow Analysis
                  2. Creating Flow
                    1. Reducing Bottlenecks
                      1. Balancing Workloads
                        1. Eliminating Interruptions
                        2. Establishing Pull System
                          1. Demand-Driven Production
                            1. Kanban Systems
                              1. Customer-Triggered Activities
                              2. Pursuing Perfection
                                1. Continuous Improvement
                                  1. Employee Involvement
                                    1. Systematic Problem Solving
                                  2. Identifying and Eliminating Waste (Muda)
                                    1. The Eight Wastes (DOWNTIME)
                                      1. Defects
                                        1. Causes and Prevention
                                          1. Quality Control Methods
                                          2. Overproduction
                                            1. Impact on Inventory and Costs
                                              1. Production Scheduling
                                              2. Waiting
                                                1. Sources of Delay
                                                  1. Queue Management
                                                  2. Non-Utilized Talent
                                                    1. Employee Engagement
                                                      1. Skills Development
                                                      2. Transportation
                                                        1. Unnecessary Movement of Materials
                                                          1. Layout Optimization
                                                          2. Inventory
                                                            1. Excess Stock and Storage
                                                              1. Inventory Management
                                                              2. Motion
                                                                1. Inefficient Movements
                                                                  1. Workplace Design
                                                                  2. Extra-Processing
                                                                    1. Unnecessary Steps or Features
                                                                      1. Process Simplification
                                                                    2. Waste Identification Techniques
                                                                      1. Gemba Walks
                                                                        1. Process Observation
                                                                          1. Value Stream Analysis
                                                                          2. Waste Elimination Strategies
                                                                            1. Root Cause Analysis
                                                                              1. Process Redesign
                                                                                1. Technology Solutions
                                                                              2. Key Lean Tools and Techniques
                                                                                1. 5S Workplace Organization
                                                                                  1. Sort (Seiri)
                                                                                    1. Removing Unnecessary Items
                                                                                      1. Red Tag Strategy
                                                                                      2. Set in Order (Seiton)
                                                                                        1. Organizing Tools and Materials
                                                                                          1. Visual Management
                                                                                          2. Shine (Seiso)
                                                                                            1. Cleaning and Inspection
                                                                                              1. Maintenance Standards
                                                                                              2. Standardize (Seiketsu)
                                                                                                1. Creating Standards
                                                                                                  1. Documentation
                                                                                                  2. Sustain (Shitsuke)
                                                                                                    1. Maintaining Discipline
                                                                                                      1. Audit Systems
                                                                                                    2. Value Stream Mapping (VSM)
                                                                                                      1. Current State Mapping
                                                                                                        1. Documenting Existing Processes
                                                                                                          1. Data Collection
                                                                                                            1. Process Flow Documentation
                                                                                                            2. Future State Mapping
                                                                                                              1. Designing Improved Processes
                                                                                                                1. Identifying Improvements
                                                                                                                  1. Implementation Planning
                                                                                                                  2. Value Stream Analysis
                                                                                                                    1. Lead Time Analysis
                                                                                                                      1. Cycle Time Measurement
                                                                                                                        1. Waste Identification
                                                                                                                      2. Kaizen (Continuous Improvement)
                                                                                                                        1. Kaizen Events (Blitz)
                                                                                                                          1. Rapid Improvement Workshops
                                                                                                                            1. Event Planning
                                                                                                                              1. Team Formation
                                                                                                                              2. Daily Kaizen
                                                                                                                                1. Ongoing Small Improvements
                                                                                                                                  1. Employee Suggestions
                                                                                                                                    1. Problem Solving
                                                                                                                                    2. Kaizen Implementation
                                                                                                                                      1. Change Management
                                                                                                                                        1. Sustainability
                                                                                                                                      2. Kanban (Visual Signal System)
                                                                                                                                        1. Kanban Boards
                                                                                                                                          1. Visual Workflow Management
                                                                                                                                            1. Card Systems
                                                                                                                                            2. Work-in-Progress (WIP) Limits
                                                                                                                                              1. Flow Control
                                                                                                                                                1. Bottleneck Management
                                                                                                                                                2. Kanban Implementation
                                                                                                                                                  1. System Design
                                                                                                                                                    1. Rules and Policies
                                                                                                                                                  2. Poka-Yoke (Mistake-Proofing)
                                                                                                                                                    1. Error Prevention Devices
                                                                                                                                                      1. Physical Constraints
                                                                                                                                                        1. Warning Systems
                                                                                                                                                        2. Error Detection Methods
                                                                                                                                                          1. Inspection Systems
                                                                                                                                                            1. Feedback Mechanisms
                                                                                                                                                            2. Implementation Strategies
                                                                                                                                                              1. Design Integration
                                                                                                                                                                1. Cost-Effective Solutions
                                                                                                                                                              2. Just-In-Time (JIT) Production
                                                                                                                                                                1. Reducing Inventory
                                                                                                                                                                  1. Inventory Minimization
                                                                                                                                                                    1. Storage Optimization
                                                                                                                                                                    2. Synchronizing Production with Demand
                                                                                                                                                                      1. Demand Forecasting
                                                                                                                                                                        1. Production Scheduling
                                                                                                                                                                        2. JIT Implementation
                                                                                                                                                                          1. Supplier Relationships
                                                                                                                                                                            1. Quality Requirements
                                                                                                                                                                          2. Takt Time
                                                                                                                                                                            1. Calculating Takt Time
                                                                                                                                                                              1. Customer Demand Analysis
                                                                                                                                                                                1. Available Work Time
                                                                                                                                                                                2. Aligning Production Pace
                                                                                                                                                                                  1. Capacity Planning
                                                                                                                                                                                    1. Resource Allocation
                                                                                                                                                                                    2. Takt Time Applications
                                                                                                                                                                                      1. Line Balancing
                                                                                                                                                                                        1. Performance Measurement
                                                                                                                                                                                      2. Heijunka (Production Leveling)
                                                                                                                                                                                        1. Smoothing Production Schedules
                                                                                                                                                                                          1. Demand Leveling
                                                                                                                                                                                            1. Mixed Model Production
                                                                                                                                                                                            2. Reducing Fluctuations
                                                                                                                                                                                              1. Capacity Utilization
                                                                                                                                                                                                1. Resource Stability
                                                                                                                                                                                              2. Jidoka (Autonomation)
                                                                                                                                                                                                1. Stopping for Defects
                                                                                                                                                                                                  1. Quality at Source
                                                                                                                                                                                                    1. Immediate Problem Solving
                                                                                                                                                                                                    2. Empowering Operators
                                                                                                                                                                                                      1. Authority to Stop
                                                                                                                                                                                                        1. Problem Escalation
                                                                                                                                                                                                      2. Gemba (Go and See)
                                                                                                                                                                                                        1. Gemba Walks
                                                                                                                                                                                                          1. Direct Observation
                                                                                                                                                                                                            1. Management Presence
                                                                                                                                                                                                            2. Observing Processes Firsthand
                                                                                                                                                                                                              1. Problem Identification
                                                                                                                                                                                                                1. Improvement Opportunities

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                                                                                                                                                                                                          1. Introduction to Lean Six Sigma

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                                                                                                                                                                                                          3. The Six Sigma Framework