Know about - Lean, Lean Six sigma, Lean tools and techniques, Lean Approach in manufacturing and service industries , How to initiate Lean practices ?

1. “A Quality System Approach towards Organizational Excellence”
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2. Lean
Six
Sigma:
— “Lean” means “without waste”
— The term Six Sigma originated from terminology associated with manufacturing,
specifically terms associated with statistical modeling of manufacturing processes.
The maturity of a manufacturing process can be described by a sigma rating indicating
its yield or the percentage of defect-free products it creates. A six sigma process is
one in which 99.99966% of the products manufactured are statistically expected to be
free of defects (3.4 defective parts/million), although this defect level corresponds to
only a 4.5 sigma level. Motorola set a goal of "six sigma" for all of its manufacturing
operations, and this goal became a by-word for the management and engineering
practices used to achieve it.
— Six Sigma is a set of techniques and tools for process improvement. It was developed
by Motorola in 1986. Jack Welch made it central to his business strategy at General
Electric in 1995. Today, it is used in many industrial sectors.
— “Lean Six Sigma” means “Elimination of wastages from entire Business model by
using six sigma methodology.”
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3. FOUNDATION
5S Key Matrices
Visual Controls Dashboard Displays
TPM Skill Matrix Deployment
1. Problem Known
Cause Known
- Kaizen Blitz
- Control plans
- Poka Yoke
- Automation
- SMED
- CFM
- Just do it !
2. Problem Known
Cause Un known
- Fishbone Diagrams
- DOE
- KTA
- Hypothesis Testing
- Regression Analysis
4. Problem Un known
Unrecognized
- FMEA
- HACCP
- PPA
- TRIZ
- QFD
- DFSS
3. Problem Suspected
But Un known
- SIPOC
- Process Mapping
- Value Stream Mapping
- Control Charts
- Capability Analysis
Supporting
Tools
Gauge
R&R
Pareto
Analysis
Affinity
Diagram
Force
field
Analysis
Team
Chartering
Brain
Storming
VOC
RACI
House
of
LEAN
Six
Sigma
M A D VD
M A I
CD
I
C
M A I
CD
M A I
C
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4. Lean:
Lean is a process management philosophy derived mostly from the Toyota Production System (TPS). It
is a powerful method that allows organizations to improve the productivity, efficiency, and quality of their
products or services. Companies today, from a wide range of industries, government agencies and
other areas are finding ways to apply the principles of lean as a means of producing goods and
delivering services that creates value for the customer with the minimum amount of waste and the
highest level of quality.
Lean manufacturing, Lean Enterprise, or lean production, often simply, "lean", considers the expenditure
of resources in any aspect other than the direct creation of value for the end customer to be wasteful,
and thus a target for elimination. Working from the perspective of the client who consumes a product or
service, "value" is any action or process that a customer would be willing to pay for.
For many, lean is the set of "tools" that assist in the identification and steady elimination of waste
(muda). As waste is eliminated quality improves while production time and cost are reduced. A non
exhaustive list of such tools would include: SMED, Value Stream Mapping, Five S, Kanban (pull
systems), poka-yoke (error-proofing), Total Productive Maintenance, elimination of time batching, mixed
model processing, Rank Order Clustering, single point scheduling, redesigning working cells, multi-
process handling and control charts (for checking mura).
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5. 5SManagement
• SERI
• SEITON
• SEISO
• SEIKETSU
• SHITSUKE
• KAIZEN
Visualization
• Shop floor
Layout
• Visualization
of 3 moving
items-
Physical
goods,
standardized
work ,
Management
Information –
KPI’s
• Color coding
• Andon
System
• Visual
Controls
• Identification
of abnormal
things
Eliminate/ReduceNVA’s
• VSM
• OEE
• Layout
• Multi
machine
manning
• Line
Balancing
• Quick
Change Over
– SMED
• Lead time
reduction
• Inventory
Turn Over
ratio
• Human Error
prevention
• SPF
• Low cost
Automation
TotalProductiveMaintenance
• Autonomous
Maintenance
(Jishu Hozon)
• Preventive
Maintenance
• Spare parts
management
• Break Down
Management
• Predictive
maintenance
• Individual
Improvement
(Kobetsu
Kaizen)
• Quality
Maintenance
• Education and
training
• Safety, health
& environment
• Development
Management
• Office TPM
QuickResponseTeam
• Multi
skilling
• Andon
System
• Trouble
shooting
analysis
KANBAN
• Customer
order driven
production
scheduling
• Pull system-
Make to order
• JIT- Inventory
management
• Multi skilling
q How to integrate & implement Lean Practices?
5
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6. 6
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