Lean Six Sigma

Lean Six Sigma

Lean Six Sigma is a method based on collaboration within a team in order to improve performance by systematically removing wastefulness and reducing deviations. It combines Lean Manufacturing / Lean Enterprise and Six Sigma in order to remove the eight types of wastefulness:

  • Overproduction
  • Stocks
  • Waiting and idle time
  • Unnecessary movements
  • Transportation
  • Incorrect procedures and processes
  • Rejections and rework
  • Unexploited talent

The DMAIC process as a systematic procedure in Lean Six Sigma projects

DMAIC process within lean six sigma

DMAIC process within lean six sigma

DEFINE phase: A common understanding of the project, its demarcation and central requirements

Element examples: Project order / project organisation / demarcation / multi-generation plan / change management / project risk analysis / process depiction (SIPOC) / customer requirements (VoC: Voice of the Customer, CTQ: Critical to Quality) / House of Quality (QFD1) / prioritisation tools etc.

MEASURE phase: A common understanding of the process performance  

Element examples: Definition of output measured values/ operational definition / data types / position and scatter/ data collection bases / spot checks / measuring system analysis (MSA) / types of variation / variation presented graphically / statistical process controls (SPC) / process capability / quality indicators etc.

ANALYZE phase: A common understanding of central causes

Element examples: Develop potential causes (Ishikawa, FMEA) / process analysis / value stream diagrams / Makigami / value analyses / bottleneck analyses / process efficiency / detection of patterns in data / bases of statistical tests and analysis methods / correlation and regression bases / statistical hypothesis tests / ANOVA procedures/ insight into design of experiments (DoE) / derivation of core causes etc.

IMPROVE phase: A common understanding of relevant solutions

Element examples: Prepare alternative solutions / derive basic concepts / assess basic concepts / lean criteria for process optimisations / solution selection and implementation / target processes / pilot testing / process simulation basics / process management development etc.

CONTROL phase: Common understanding of mechanisms for sustainable implementation

Element examples: Target processes / procedure instructions (SOPs) /  / statistical process control (SPC) / finalisation of process management diagrams / reaction plans etc.

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