This document provides an introduction to Lean Six Sigma. It discusses various related terms like Lean, Six Sigma, 5S, Kaizen and Poka-Yoke. Lean aims to eliminate waste from processes. Six Sigma measures variability in processes and aims for 3.4 defects per million opportunities. The document outlines the DMAIC process for Six Sigma implementation, which includes Define, Measure, Analyze, Improve and Control steps. It provides details on each step and how they help improve processes by reducing waste.

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An Introduction to
Lean Six Sigma
Business Beam (Pvt.) Limited

2. Too Many Buzzwords, Which One to
Chose?
 Lean
 Six Sigma
 5S
 Kaizen
 Poka-Yoke
 and many more…
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3. Which track will help you run
Marathon in min. possible time?
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4. Logical Improvement Steps
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 Lets remove hurdles first…
This is Lean!!!

5. What is Lean?
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 Lean manufacturing or lean production, often simply “Lean”, is a
production practice that targets for elimination of waste.
 What is Waste?
 Anything other than the minimum amount of equipment,materials, parts,
space, and worker’s time which are absolutely necessary to add value to
the product.
 For example:
 Defects
 Overproduction
 Waiting
 Non-utilized resources
 Transportation
 Inventory
 Extra processing

6. Results of Lean
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COST QUALITY DELIVERY
(CycleTime)
Low Cost
 Lower working capital
 Less scrap and rework
 Higher productivity
High Quality
 Receive feedback at
more frequent
intervals
 Introduce design/
quality improvements
at a more rapid rate
Fast Response to Market
 Shorter delivery time
 Faster to market with
new products
 Improved market
share

7. Related Terms
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 There are several related terms
 Kaizen
 6S
 PokaYoke
 Just InTime
 TQM

8. Kaizen
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 Kaizen is the organized use of common sense to improve
cost, quality, delivery, and responsiveness to customer
needs.
 Five components of Kaizen are:
 Teamwork
 Personal discipline
 Improved morale
 Quality circles
 Suggestions for improvement

9. 6S (5S plus Safety)
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Sort Set in Order SustainStandardizeShine

10. Poka Yoke
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 A poka-yoke device is any mechanism that either prevents
a mistake from being made or makes the mistake obvious
at a glance.
 The goal of poka-yoke is both prevention and detection:
“errors will not turn into defects if feedback and action
take place at the error stage.”

11. Six Sigma
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 A Measure ofVariability
 How much Data falls within Customers’ Requirements
 3.4 Defect per Million Opportunities or
 99.99996% of Data or Opportunities
 Higher the Process Sigma
 The more Outputs meet Customers’ Requirements or
 The fewer the Defects.

12. Performing at Six Sigma
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.00034% Defects (Products
Unacceptable to Customer)
Mean
Variation
Product or Service Output
99.99966% Products
Acceptable to customer

13. Six Sigma Implementation
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DEFINE MEASURE ANALYZE IMPROVE CONTROL
DMAIC

14. 1. Define
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 Activities performed
 Map Current State
 Customers
 Demand Rate
 Processes
 Suppliers
 Storage Locations
 Product Flow
 Information Flow
DEFINE

15. 2. Measure
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 Activities performed
 Measure Inventory
 Total LeadTime
 Total CycleTime
 Process Time
 Cycle Efficiency
MEASURE

16. How far would you drive
without your gauges?

18. 3. Analyze
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 Activities performed:
 IdentifyWaste
 Over Producing
 Inventory
 Waiting
 Motion
 Transportation
 Defects
 Processing
 Build Strategy
 Build To Order
 AssembleTo Order
 Finish To Order
 EngineerTo Order
 Identify the Pacemaker
 Identify Issues
ANALYZE

19. 4. Improve
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 Activities performed
 Kaizen
 Map Future State
 Demand
 Create Flow from Pacemaker
 Create Pull from Pacemaker
 Calculate Inventory amounts
 Safety Stock
 Buffer Sizes
IMPROVE

20. 5. Control
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 Activities performed
 Create metrics to maintain Future State
 Continuously Improve
CONTROL

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