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Understanding Lean Six Sigma (Lean Manufacturing)

About Workshop

Lean Six Sigma, is a marriage of two otherwise distinct business management strategies, lean manufacturing and Motorola's Six Sigma system. While the lean manufacturing methodology concentrates on creating more value with less work,the Six Sigma system strives to identify and eliminate defects in product development. Lean Six Sigma is a combination of two powerful and proven process improvement methods (Lean and Six Sigma) that builds on existing organization capability in quality, statistics, and project execution. It is also known as the Toyota Production System. The goal of lean production is to get the right things to the right place at the right time, the first time, while minimizing waste and being open to change. In addition to eliminating waste, the methodology also brings improved product flow and better quality.

Lean six sigma is a systematic approach which reduces waste in the value stream. It not only covers defective products, but all types of defective work. It identifies defects, overproduction, inventories (in process or finished goods), unnecessary processing, unnecessary movement of people, unnecessary transport of goods, waiting time, and services that don't meet customer's needs. It encompasses the three core principles:

1) The DMAIC (Define, Measure, Analyze, Improve and check)

2) DMADV (Define, Measure, Analyze, Design, and Verify)

3) Waste Reduction

This results in developing manufacturing processes that consistently meet customer requirements in terms of target costs, target release dates, and manufacturing requirements.

The principles of lean production enables to deliver on demand, minimize inventory, maximize the use of multi-skilled employees, flatten the management structure, and focus resources where they were needed.

This course aims at imparting and enhancing the participants understanding on Lean Six Sigma approach for process improvements.

How participants will benefit after the course
Upon completion of this training, participants are expected to have conceptual understanding of Lean Six Sigma Manufacturing approach. With extensive class room exercises and case studies participants are expected to have hands on experience on waste elimination and process streamlining for business benefits.

By the end of the program, participants shall be ready to engage others in value stream mapping and plan Kaizan using the Lean thinking, tools and concepts at their work places.

Workshop topics to be covered:

Introduction to Lean Six Sigma
What is lean Six Sigma? Why Lean Six Sigma?
History and Philosophy
What is scientific and Practical?
Batch Manufacturing Vs Lean Manufacturing
Relation with organizational excellence
Formulating Team and project charter
Key attributes of Lean sigma members
Sponsor, Champion, Black belts, green belt, yellow belt.
Identify and select project for Lean sigma initiative

Lean Sigma Implementation Roadmap
Pull Vs push system
What is waste?
Classifying waste types?
5S implementation
What is CTQ
What is JIT
JIT/lean streamlines production
Lean/JIT Goals and Building Blocks
Lean manufacturing tools and methodology
Business process reengineering and Lean Sigma Implementation

Lean Sigma Implementation
Lean manufacturing tools and methodology(Continued)
Product design(standard parts, modular design, quality in design concurrent Engineering)
Process design (small batch size, setup time reduction, manufacturing cells, limited work in process, quality improvement, production flexibility, little inventory storage)
SMED ( Single Minute Exchange of Die)
Fool Proofing Poka – Yoke
Production methods & Kaizen
Personnel/organization elements
Inventory is an Asset or Evil

Lean Sigma Implementation and Sustenance
Visual systems (Kanban)
Understanding Andon
level capacity loading
Manufacturing planning and control for lean sigma initiative
TPM (Total Productive Maintenance)
Autonomous Maintenance
Preventive maintenance
Predictive maintenance
Overall Equipment Effectiveness (OEE)
Setting up Managing points and Control points (KRA and KPI)
Project closure (Control Plans and Sustenance tools)

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