Lean Six sigma tools and techniques

Presented by : Nikunj Rana

Lean Six Sigma • Lean Six Sigma and its tools have created an impact in the

operations of many companies. • Lean and Six Sigma tools can be utilized to promote improvements

in quality both as a systematic and strategic manner.• Most of the taught Lean Six Sigma tools are quality techniques

that are not really new. What can be different is simply the application and integration of the tools.

• Lean Six Sigma tools are included in its Define-Measure-Analyze-Improve-Control (DMAIC) improvement project execution roadmap. This roadmap’s execution is to create robust processes that let businesses attain standards that are high and in control.

• In Lean Six Sigma, data are subjected to analysis in order to better comprehend problems and identify customer needs. The phases of Lean Six Sigma are to quantify possible defects and its causes, along with the reduction of process waste.

Module 1 Yellow Belt Training 3

Tools to be Learned• Team Problem Solving and Team Effectiveness (Working in Teams)

– Cross-Functional Teams– Characteristics of Effective Team Meetings– Project Charters and Meeting Agendas

• Voice of the Customer (Knowing What is Important)– Sources of the Voice of the Customer– Critical-to-Quality Factors and Critical Customer Requirements

• Idea Generation and Grouping (Working with Ideas)– Brainstorming; Force Field Analysis– Cause-and-Effect Diagram / 6Ms; Root Cause Analysis / 5 Why’s– Affinity Diagram; Nominal Group Technique; Multi-voting

• Data Collection, Analysis and Presentation (Working with Numbers)– Process and Business Metrics– Data Collection Plan– Check Sheet, Process Study Log and Other Data Collection Forms– Data Stratification and Segmentation– Histogram, Run Chart, Control Chart and Other Graphical Presentations of Data

Module 1 Yellow Belt Training 4

Tools to be Learned, con’t• Decision-making Tools (Working with Facts)

– Pareto Analysis; Pareto Chart– Understanding and Explaining Process Variation– Cause-and-Effect Matrix and Other Prioritization & Selection Tools

• Speed and Flow Implementation (Ensuring Value)– Process Mapping and Flowcharts– Value-Add vs. Non-Value-Added– 5S / Workplace Organization– Spaghetti Diagram (Workflow) and Work Cell Layout– Quick Changeover: Setup and Changeover Reduction– Pull-based Flow and Replenishment

• Defect Prevention and Mistake-Proofing (Quality at the Source)– Standardized Work and Best Practices– Visual Workplace: Visual Aids and Learning Tools– Poka-Yoke (Mistake-Proofing) Devices– Preventative Maintenance (Total Productive Maintenance)– Design Simplification and Parts Rationalization

5 why technique

Fishbone diagram

A fishbone diagram is a structured tool for brainstorming.

Histogram

Regression Analysis

Run chart/Time series

DMAIC Roadmap