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1. 1
Lean-Insight.com
Lean Six Sigma Training
Part 15
Training Centers: Bangalore, Chennai and Hyderabad

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Mistake proofing (Categories of Poka-Yoke)
A detection device signals the user when a mistake has been made, so that
the user can quickly correct the problem
EG: The U.S. Consumer Product Safety Commission has recorded 105 deaths
that were caused by wheelchairs rolling away from the person.
The response? A mistake-proofing device that locks the wheelchair when no
one is sitting in it. An unlocking lever on the handle allows the wheelchair to
be moved when empty.
Eliminate unnecessary or duplicate steps
Use flow charts to visualize the process
Keep it simple
You don’t have to spend a lot of money
Use many Poka-Yoke devices in a process
There isn’t a quota on how many you can use
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3. 3
Action Workout (AWO)…The Change Process
•AWO is the Kaizen or change process to apply the
lean tools…target waste
•Not traditional Workout…Intense Focus on “Action”
and Speed
•Key Concept: Try storm (Vs Brainstorm)
•New ideas are tried quickly, observe results
•Quick iterations: try-observe-improve…repeat
•No Money…it’s about creativity, not $ solutions
Hands on…Turn Ideas into Action!
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4. 4
A lean event is a process
Present3 Wks Prior 2 Wks Prior AWO Week1 Wk Prior4 Wks Prior
Conduct Analysis to further
define Scope
Kickoff
Meeting
Define Project; CTQs; VOC
Goals & Objectives
LEAN EVENT
Finalize Setup Needs;
Finalize Analysis
Follow-up with Kaizen
Newspaper Items
Continuous Training and Information Sharing/Updates; Team Meetings
Gathered Data and define
Hi-level process map;
Set initial target sheet;
D DM AI ICM A
The AWO event is the “I” in DMAIC
The AWO
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5. 5
Culture and Leadership
Culture and Leadership
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6. 6
The Investment Required
New
Technical
Thinking
Change
Culture
Dollars
It’s not about spending Money…
“Retooling” the way people think is the Key
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7. 7
“Retooling” The Culture…Leadership
Leadership
Leader
Supporter
Blocker
Status Quo
Inconsistent
Sustainable
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8. 8
Leaders Self Assessment
Blocker
Supporter
Leader
• No Engagement
• We’re “Already Lean”
• “It Will Go Away”
• Superficial Knowledge
• Allows AWO’s
• Grass Roots Effort
• “Wait & See”
• Passionate
• Knows the Tools
• Allocates Resources
• Sets Expectations
• Goes to the Shop
• Retools Processes:
- HR
- P&E
- Metrics
Lean-Insight.com

9. 9
Getting Started
•Be a Change Agent
•Get some Knowledge (See resources)
•Map your Value Streams…identify waste
•Prioritize Plan of attack…consider Model approach
•Do an AWO…implement improvements
•Develop an AWO plan and implement
Lean-Insight.com

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Change Management Objective
People’s perceptions of a change process follow a predictable pattern.
The goal of change management is to “manage” the emotional cycle and even out
the peaks and valleys. This does not mean that change management eliminates
“fear,” it simply manages it.
Lean-Insight.com

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If you are looking for Lean Six Sigma Course training in Bangalore / Bengaluru along
with certification visit:
http://lean-insight.com/six-sigma-training-bangalore/