Implementing Lean Six Sigma in Industry


The rising wages and the infrastructure cost are compelling manufacturers from Bangladesh to look for efficient manufacturing systems to bring in better, if not bigger, profits. Lean Sigma combines the advantages of Lean philosophy with Six Sigma Quality Management System. Though the Apparel Manufacturers and professionals in Bangladesh are already aware on utility of the tool in waste reduction and thereby cost optimization, yet the industry is not aware of implementation methodology for specific lean tools such as Flow Manufacturing, Poka-Yoke, Andon and SMED. This workshop aims to educate the participants in understanding the step by step procedure in implementing lean Sigma in their factory.

Benefits to Participants: On successful completion of workshop, participants will understand
•The intricacies of implementing the lean manufacturing system in their factories
•Developing work cells and flow systems
•Plan Total Productive maintenance for improving overall equipment Efficiency
•Methodology of implementing Poka Yoke, and arresting potential failure modes for implementing right first time system


Through rigorous class room exercises, case studies and role plays participants are expected to gain knowledge of various tools such as Quick Wins, Six Hat Thinking, Cause Effect Matrix, Autonomous Maintenance, Failure Mode Effect Analysis and Six Sigma Projects. Extensive experience sharing in implementing Lean Six Sigma initiative in Apparel and service industry will benefit all professionals desirous of identifying scientific method for continuous improvement.

Contents of Training:

Day 1

Session 01
Introduction to Lean Sigma Why and How for my Business?
•Why 'Manufacturing Excellence, when my buyer/Customer does not demand it?
•Why 100% inspection is not 100% perfect?
•Why current manufacturing and inspection system fail to give desired results?
•What is Lean (Manufacturing) (Six) Sigma?
•Lean Sigma Tool Set
•The Lean Simulation Game- (simulation exercise for understanding lean Manufacturing) exercise for understanding Lean Manufacturing)

Session 02
Implementing Lean Sigma Towards Manufacturing Excellence
•Developing Team Charter
•Collecting voice of customer Understanding Critical to Quality (CTQ) examples and Case Studies of Internal and External Customers (Buyer/Retailer Requirement Mapping)
•Empowering the lower management and operators in bringing improvements - KAIZEN, 55, Visual Control (Classroom Exercise with Case Study)
•Implementing Autonomous Maintenance and how they help on cutting and sewing floor (experience sharing).
•One Point Lesson

Session 3
Implementing Lean Sigma Towards Manufacturing Excellence
•Implementing Quick Wins (Classroom Exercise with case Study)
•Understanding PDCA Cycle
•How to adapt to KanBan, JIT, Vendor Bays and Pull Systems in Apparel Manufacturing
•Developing a ‘mistake proof' system for garment manufacturing Poka Yoke
•How to control Fire Fighting on Apparel Shop Floor Develop Management System Chart.
•Experience Sharing on implementing lean Sigma in Apparel and Textile Factories
•Developing lean set up (with machine model ) demonstrating WIP reduction, through put time
reduction and productivity improvement

Day 2

Session 01
Implementing Lean Sigma Towards Manufacturing Excellence
• Develop SIPOC & Top Down Chart (Classroom Exercise for different Business Processes)
• Using Jidoka and Andon as Tools for “Right First Time in Apparel Manufacturing"
• Six Hats Thinking (Classroom Exercise and Case Study)

Session 02
Implementing Lean Sigma Towards Manufacturing Excellence
•Brain Storming (Classroom Exercise and Case Study)
• Root Cause Analysis (Classroom Exercise and case Study)
• Cause Effect Matrix (Classroom Exercise and Case Study)
• Failure Mode Effect Analysis (FMEA) for eliminating potential failure modes.
• How to reduce style change over time Implementing SMED

Session 03
Implementing Lean Sigma Control Phase
• Develop Control Charts and Control Points (Classroom Exercise and case Study)
• Define Key Result Areas (KRA) and Key Performance Indicator (KPI) for Each Work Area (case Sustaining Improvements through Control Plans and Documents
• Develop Standard Operating Procedures (SOP) and control Charts
• Process Audits
• Training Manuals
• Work Instructions
• Experience Sharing on Implementing Lean Sigma in Apparel and Textile Factories.

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9140345, 9117179 Ltd.

19 th floor (East), BDBL Building (Old BSRS)
12 Karwan Bazaar
Dhaka - 1215

Senior Management, owners and Garment Industry Professionals