Lean Six Sigma is a process that incorporates two key elements of Continuous Improvement: Lean and Six Sigma. It is a process of improvement to basically prevent problems, remove waste, increase efficiency, and improve working conditions to benefit the Customers and the organization. The combination of tools and methods of Lean and Six Sigma methodologies improves the processes and thus the entire business. To attain positive results, reduction in waste and variation should be considered by implementing the Lean Six Sigma methodology. Every employee should be involved to assure the improvement in the working environment. If every employee is satisfied by working conditions, he/she will work efficiently thus improving the profitability of the organization.
For Lean to work, an organization needs to change its culture. Lean is all about the way people think. Teaching tools leads to improvements, but they are typically just single point improvements and often do not result in breakthrough thinking, and often the improvements do not stick. The success of a Lean transformation rests with an organization’s leadership. Only when leadership leads by example will a Lean transformation succeed.
The Lean Six Sigma comprehensive set of tools and analytical techniques are used to discover and solve problems. The tools identify actual root causes, and solutions are implemented to improve operations. The process will only give the desired results if the right set of tools and techniques are implemented. An organization that believes in Continuous Improvement needs the right problem-solving tools.
To understand the methodology of Lean Six Sigma, we need to understand both Lean and Six Sigma separately.
Lean was originated at Toyota. The fundamental objective of Lean is the eradication of waste. Lean can be described as “a set of tools that help in the detection and the steady removal of waste.” If the waste removal issue is addressed successfully, then any company is set to grow while minimizing costs. The tools in Lean analyze the business process.
Effective Lean implementation involved four key steps:
1. Identify- Identify the root cause of a problem. Identification of an issue is key for any problem-solving activity. If the problem is identified appropriately, the problem-solving activities are highly effective.
2. Fix- Fix the problem. Make use of appropriate tools to fix the problem.
3. Check- Check if the problem is properly fixed. This is an important step as you always want to be alert to the possibility of a recurrence.
4. Maintain – Implement the necessary Lean tools to sustain the corrective actions.
There are five principles of Lean Manufacturing:
1. Value- The product or service that a customer considers important should be valued by us, and we should deliver value accordingly.
2. Value Stream- The steps involved in delivering products and services.
3. Flow- The uninterrupted flow of activities adds value to the customer.
4. Pull- The value stream is only processing products and services that the customer wants. We should be sure to understand the customer demand before initiating the work.
5. Perfection- The continuous assessment of delivery of products and services to the customer.
Six Sigma :
Six Sigma originated at Motorola. It focuses on reducing process variation and developing process control. The identification and elimination of anything that causes variation in the process provides process stability and product consistency. Implementation strategies can vary depending on the business goals. Technical tools like statistical data analysis, design of experiments, SPC, and hypothesis testing can be used to reduce variation.
Six Sigma includes five process improvement steps:
1. Define- The problem is defined. The process is analysed, and expectations for the process are defined from the customer’s perspective. This is done to enhance the customer experience.
2. Measure- The present performance of the process is measured to verify the actual performance.
3. Analyse- This phase analyzes the actual problem using the measured data. The true root cause is identified.
4. Improve- The possible changes are implemented, and solutions are designed and tested so that variation is reduced or eliminated.
5. Control- The measured changes are implemented, and the process is put under control. This step ensures that the implementation is done accurately.
Lean Six Sigma is one of the most influential problem solving and continuous improvement methods used by most organizations today.
There are six belt levels of Lean Six Sigma:
1. White Belt- Understands the goals and structure of Lean Six Sigma.
2. Yellow Belt- Understands basic Lean Six Sigma concepts.
3. Green Belt- Starts and manages Lean Six Sigma projects.
4. Black Belt- Has advanced Lean Six Sigma knowledge.
5. Master Black Belt- Works with leaders to identify gaps and select projects.
6. Champion- Executive leader who drives the initiative and helps the team in selecting projects.
A certified Lean Six Sigma Yellow Belt is a trained in the Lean Six Sigma methodology and tools. He/she is a part of team who leads limited improvement projects.
Quality Support Group offers Lean Six Sigma Yellow Belt Training and Certification worldwide. By attaining this certification, you will be able to use Lean tools and techniques to improve manufacturing in the organization. The customer perspective is especially important, and you need to work according to that. Implementing the tools according to the need of the organization will increase value and reduce waste.
Quality Support Group is dedicated in providing a wide range of training courses taught by the experts. If you are looking for Lean Six Sigma Training and Certification, Quality Support Group is one of the best resources to attain the knowledge necessary. Our Lean Six Sigma Yellow Belt Training is a basic Lean Six Sigma certification through which you will receive extensive training in the field. This program uses a combination of various presentations, discussion, and interactive exercises so that the concepts of the program are grasped by all the participants equally. A question and answer session offers great help to anybody who has any difficulty understanding the concepts.