Six Sigma Green Belt Certification Workshop: LECTURE 6: Lean Concepts and Tools

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Six Sigma Green Belt Certification Workshop

LECTURE 6: Lean Concepts and Tools
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ASQ Body of Knowledge I.B.1
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I. Overview: Six Sigma and the Organization

B. Lean Principles in the Organization
1. Lean Concepts and Tools
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Lean Manufacturing : Introduction
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The term Lean was first used in a literature

The machine that changed the world (1990).
By James P Womack, Daniel T Jones & Dan Roos.
To compare the production systems of American and Japan auto
industries.
This term was used to brand the principles and tools used at Toyota and
other Japanese auto industries.
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Why it was termed Lean?
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Because it uses less of everything compared to other manufacturing

philosophies:
Less human manufacturing effort.
Less the manufacturing space.
Less engineering hours to develop new product.
Less inventory on site.
Fewer defects.
And greater and ever growing variety of products.
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Manufacturing Philosophies
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Craft Manufacturing (before 1800):

Low volume
High variety
Mass manufacturing (after 1800):
Low variety
High volume
Lean manufacturing(1970..):
Combining craft & mass
High variety in batches
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Definition:
Manufacturing philosophy ,that shortens time between customer order
to payment, by eliminating waste
Best Example: Toyota Production System (TPS)
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Basic Concepts of Lean
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Value chain - Identifying the activities in the process chain:

that does not add value product/service and,
Reduce or eliminate wherever possible.
Create Flow - producing and creating near to one piece flow:
Eliminate batch and queue systems.
Reduce batch size ideally to one.
Pull production - trigger productions:
Only when there is a customer order.
Link productions through customer pull rather than push.
5S house keeping:
Clean organized work places.
Everything has a place and everything in its place.
Poke Yoke error proofing:
Mistakes cant be happened even by mistake.
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14 Principles of TPS (4P model)
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Continuous organization learning through kaizen

Go See for yourself to thoroughly understand the situation
Make decisions slowly by consensus, thoroughly, implement rapidly
Problem
Solving
People & Partners
Process
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Grow leaders who live the philosophy

Respect, develop and challenge your people and teams
Respect, challenge and develop your suppliers
Create process flow to surface problems

Use pull system to avoid overproduction
Level out workload
Stop line when there is quality problem
Standardise tasks
Use visual controls; no problems are hidden
Use only reliable, tested technologies
Management Decision based on

long term vision
Philosophy
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___________________________________

Six Sigma Green Belt Certification Workshop

I. Overview: Six Sigma and the Organization

The term Lean was first used in a literature

Copy Right RS OTIFAS (P) Ltd

Copy Right RS OTIFAS (P) Ltd

Because it uses less of everything compared to other manufacturing

Copy Right RS OTIFAS (P) Ltd

Copy Right RS OTIFAS (P) Ltd

Craft Manufacturing (before 1800):

Copy Right RS OTIFAS (P) Ltd

Copy Right RS OTIFAS (P) Ltd

Value chain - Identifying the activities in the process chain:

Copy Right RS OTIFAS (P) Ltd

Continuous organization learning through kaizen

Grow leaders who live the philosophy

Create process flow to surface problems

Management Decision based on

Copy Right RS OTIFAS (P) Ltd

Copy Right RS OTIFAS (P) Ltd

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