___________________________________

___________________________________
___________________________________

Six Sigma Green Belt Certification Workshop

LECTURE 6: Lean Concepts and Tools

___________________________________
ASQ Body of Knowledge I.B.1

___________________________________

I. Overview: Six Sigma and the Organization

B. Lean Principles in the Organization
1. Lean Concepts and Tools

___________________________________
___________________________________
Copy Right RS OTIFAS (P) Ltd

___________________________________
Lean Manufacturing : Introduction

___________________________________

The term Lean was first used in a literature

The machine that changed the world (1990).
By James P Womack, Daniel T Jones & Dan Roos.
To compare the production systems of American and Japan auto
industries.
This term was used to brand the principles and tools used at Toyota and
other Japanese auto industries.

___________________________________
___________________________________
___________________________________
___________________________________
___________________________________

Copy Right RS OTIFAS (P) Ltd

Copy Right RS OTIFAS (P) Ltd

2/8

___________________________________
Why it was termed Lean?

___________________________________

Because it uses less of everything compared to other manufacturing

philosophies:
Less human manufacturing effort.
Less the manufacturing space.
Less engineering hours to develop new product.
Less inventory on site.
Fewer defects.
And greater and ever growing variety of products.

___________________________________
___________________________________
___________________________________
___________________________________
___________________________________

Copy Right RS OTIFAS (P) Ltd

Copy Right RS OTIFAS (P) Ltd

3/8

___________________________________
Manufacturing Philosophies

___________________________________

Craft Manufacturing (before 1800):

Low volume
High variety
Mass manufacturing (after 1800):
Low variety
High volume
Lean manufacturing(1970..):
Combining craft & mass
High variety in batches

___________________________________
___________________________________
___________________________________
___________________________________

Definition:
Manufacturing philosophy ,that shortens time between customer order
to payment, by eliminating waste
Best Example: Toyota Production System (TPS)

Copy Right RS OTIFAS (P) Ltd

Copy Right RS OTIFAS (P) Ltd

___________________________________
4/8

___________________________________
Basic Concepts of Lean

___________________________________

Value chain - Identifying the activities in the process chain:

that does not add value product/service and,
Reduce or eliminate wherever possible.
Create Flow - producing and creating near to one piece flow:
Eliminate batch and queue systems.
Reduce batch size ideally to one.
Pull production - trigger productions:
Only when there is a customer order.
Link productions through customer pull rather than push.
5S house keeping:
Clean organized work places.
Everything has a place and everything in its place.
Poke Yoke error proofing:
Mistakes cant be happened even by mistake.
Copy Right RS OTIFAS (P) Ltd

Copy Right RS OTIFAS (P) Ltd

___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
5/8

___________________________________
14 Principles of TPS (4P model)

___________________________________

Continuous organization learning through kaizen

Go See for yourself to thoroughly understand the situation
Make decisions slowly by consensus, thoroughly, implement rapidly

Problem
Solving
People & Partners

Process

___________________________________

Grow leaders who live the philosophy

Respect, develop and challenge your people and teams
Respect, challenge and develop your suppliers

Create process flow to surface problems

Use pull system to avoid overproduction
Level out workload
Stop line when there is quality problem
Standardise tasks
Use visual controls; no problems are hidden
Use only reliable, tested technologies

Management Decision based on

long term vision

Philosophy

Copy Right RS OTIFAS (P) Ltd

___________________________________
___________________________________
___________________________________
___________________________________

Copy Right RS OTIFAS (P) Ltd

6/8