F1. What is Lean Six Sigma?

Summary

Lean Six Sigma is a comprehensive approach to process improvement, combining the waste elimination principles of Lean with the variation reduction techniques of Six Sigma. Originating from Toyota in the 1940s and Motorola in the 1980s, it uses metrics to measure process capability and methodologies like DMAIC and DMADV for existing and new processes, respectively. The goal is to achieve high conformance rates, reduce defects to 3.4 per million opportunities, and ultimately satisfy customers while minimizing losses, leading to significant operational savings.

Takeaways

• 📏 Lean Six Sigma is a metric used to measure process capability, with a Six Sigma level process producing only 3.4 defects per million opportunities.
• 🛠️ It is a methodology with two main approaches: DMAIC (Define, Measure, Analyze, Improve, Control) for existing processes and DMADV (Define, Measure, Analyze, Design, Verify) for new processes.
• 🏢 Lean Six Sigma is also a management system that has been widely adopted by companies for its effectiveness in process improvement and cost reduction.
• 📉 The goal of Lean Six Sigma is to reduce process variation, aiming for a conformance rate of 99.999996%, which equates to 3.4 defects per million opportunities.
• 🤝 Lean and Six Sigma are combined to form Lean Six Sigma, integrating the practical waste elimination approach of Lean with the statistical variation reduction of Six Sigma.
• 📈 Lean Six Sigma is data-driven, focusing on reducing unacceptable products or events to achieve customer satisfaction and minimize losses.
• 📚 The course will teach the high-level approach of the DMAIC methodology, which is fundamental for Yellow Belt students.
• 🚀 The origins of Lean Six Sigma lie in two separate bodies of knowledge: Lean, introduced by Taiichi Ohno in the 1940s, and Six Sigma, developed by Bill Smith and Dr. Michael J Hardy at Motorola in the 1980s.
• 🌐 Lean Six Sigma has evolved as a powerful methodology for driving operational excellence by combining the practical and statistical aspects of Lean and Six Sigma.
• 🔍 The course will delve into the specifics of Lean Six Sigma, including its problem-solving approach and specialized tools for process and product improvement.

Q & A

What is Lean Six Sigma?

Lean Six Sigma is a methodology that combines Lean's focus on waste elimination with Six Sigma's emphasis on reducing process variation. It is a metric, methodology, and management system used to improve processes, reduce defects, and increase efficiency.

What does the term '3Ms' in Lean Six Sigma refer to?

The '3Ms' in Lean Six Sigma refer to Metric, Methodology, and Management System. These are the three fundamental components that define Lean Six Sigma.

How is Lean Six Sigma defined as a metric?

As a metric, Lean Six Sigma measures the capability of a process to conform to certain requirements. A process that follows a Six Sigma level produces only 3.4 defects per million opportunities, indicating a higher level of quality compared to lower Sigma levels.

What are the two methodologies under the Lean Six Sigma body of knowledge?

The two methodologies under Lean Six Sigma are DMAIC (Define, Measure, Analyze, Improve, Control) for existing processes, and DMADV (Define, Measure, Analyze, Design, Verify) for new processes, products, or services.

What is the significance of the 3.4 defects per million opportunities in Six Sigma?

The 3.4 defects per million opportunities is a benchmark for Six Sigma quality levels, representing a conformance rate of 99.9999967%. It signifies a high level of process capability and minimal defects.

How does Lean Six Sigma serve as a management system?

As a management system, Lean Six Sigma is deployed by companies to improve their processes, resulting in significant cost savings and operational efficiency. It provides a structured approach to process improvement and cost reduction.

What is the goal of Lean Six Sigma in terms of reducing unacceptable products or events?

The goal of Lean Six Sigma is to reduce the number of unacceptable products or events to a minimal level, aiming for a conformance rate of 99.9999967%, which equates to 3.4 defects per million opportunities.

What is the origin of Lean in Lean Six Sigma?

Lean originated from the Toyota Production System introduced by Taiichi Ohno in the 1940s. It focuses on waste elimination and is considered the practical side of the Lean Six Sigma approach.

Who introduced Six Sigma, and what does it focus on?

Six Sigma was introduced by Bill Smith and Dr. Michael J. Harry at Motorola in the 1980s. It focuses on variation reduction and is considered the statistical side of the Lean Six Sigma approach.

What is the ultimate goal of Lean Six Sigma initiatives?

The ultimate goal of Lean Six Sigma initiatives is to satisfy customers by delivering high-quality products and services while minimizing losses and maximizing process efficiency.

How does Lean Six Sigma combine the practical and statistical aspects of process improvement?

Lean Six Sigma combines the practical waste elimination approach of Lean with the statistical variation reduction techniques of Six Sigma, creating a powerful methodology for driving operational excellence.

Outlines

00:00

📏 Introduction to Lean Six Sigma

This paragraph introduces the concept of Lean Six Sigma, a methodology for process improvement and problem-solving. It explains that Lean Six Sigma is a metric for measuring process capability, with a Six Sigma level process producing only 3.4 defects per million opportunities. The paragraph outlines the two methodologies under Lean Six Sigma: DMAIC (Define, Measure, Analyze, Improve, Control) for existing processes and DMADV (Define, Measure, Analyze, Design, Verify) for new processes. The goal of Lean Six Sigma is to reduce unacceptable products or events to a conformance rate of 99.999967%, ultimately aiming to satisfy customers and minimize losses. The origins of Lean Six Sigma are also discussed, highlighting its combination of the practical waste elimination approach of Lean, introduced by Taiichi Ohno at Toyota in the 1940s, and the statistical variation reduction approach of Six Sigma, introduced by Bill Smith and Dr. Michael J. Harry at Motorola in the 1980s.

05:02

🚀 Driving Operational Excellence

The second paragraph emphasizes the power of Lean Six Sigma in driving operational excellence. It suggests that the combination of Lean and Six Sigma methodologies results in a more effective approach to improving processes and products. The paragraph is brief but carries the significant message that Lean Six Sigma is a go-to methodology for companies seeking to cut operational costs and enhance their processes, thereby achieving operational excellence.

Keywords

💡Lean Six Sigma

Lean Six Sigma is a methodology that combines Lean principles, which focus on eliminating waste, with Six Sigma's emphasis on reducing process variation and improving quality. It is a comprehensive approach to operational excellence, aiming to minimize defects and maximize customer satisfaction. In the script, Lean Six Sigma is introduced as a metric, methodology, and management system, highlighting its role in process improvement and cost reduction.

💡Metric

In the context of Lean Six Sigma, a metric is a measure used to assess the performance of a process. The Six Sigma metric specifically quantifies the capability of a process to meet customer requirements, with a Six Sigma level process producing only 3.4 defects per million opportunities. The script explains that higher Sigma levels indicate better process performance.

💡Methodology

Methodology in Lean Six Sigma refers to the structured and proven step-by-step processes used to manage, improve, or explore a process. The script mentions two methodologies: DMAIC (Define, Measure, Analyze, Improve, Control) for existing processes and DMADV (Define, Measure, Analyze, Design, Verify) for new processes, products, or services.

💡Management System

A management system in Lean Six Sigma is a framework that organizations use to deploy and institutionalize the methodology across their operations. The script notes that Lean Six Sigma has been widely adopted by companies due to its proven track record in helping them improve processes and achieve significant savings.

💡Defects per Million Opportunities (DPMO)

Defects per Million Opportunities is a statistical measure used in Six Sigma to quantify the number of defects in a process. The script states that a Six Sigma level process produces only 3.4 DPMO, which equates to a conformance rate of 99.9999967%, indicating a high level of quality.

💡Lean

Lean is a philosophy and set of practices aimed at eliminating waste within a process. Introduced by Taiichi Ohno at Toyota in the 1940s, Lean is the practical side of the Lean Six Sigma approach, focusing on efficiency and value creation for the customer. The script discusses Lean in the context of waste elimination.

💡Six Sigma

Six Sigma is a set of techniques and tools for process improvement that focuses on reducing variation and defects in manufacturing and business processes. Originated at Motorola in the 1980s, Six Sigma is the statistical side of Lean Six Sigma, as mentioned in the script.

💡Waste Elimination

Waste elimination is a core principle of Lean, aiming to remove any activity that consumes resources but does not add value. The script discusses waste in the context of Lean, emphasizing its importance in the combined Lean Six Sigma approach.

💡Operational Excellence

Operational excellence refers to the continuous improvement of business operations to achieve high performance and efficiency. The script mentions Lean Six Sigma as a powerful methodology for driving operational excellence by reducing defects and process variation.

💡DMAIC

DMAIC is an acronym for Define, Measure, Analyze, Improve, Control, which is a structured problem-solving process used in Six Sigma for improving existing processes. The script explains DMAIC as the methodology to be taught in the Yellow Belt course.

💡DMADV

DMADV stands for Define, Measure, Analyze, Design, Verify, and is another structured problem-solving process used in Six Sigma for creating new processes, products, or services. The script mentions DMADV as the second methodology under the Lean Six Sigma body of knowledge.

Highlights

Lean Six Sigma is defined by metrics, methodology, and management system.

3.4 defects per million opportunities is the Six Sigma level benchmark for process capability.

Higher Sigma levels indicate superior process performance.

Lean Six Sigma methodologies include DMAIC for existing processes and DMADV for new processes, products, or services.

DMAIC stands for Define, Measure, Analyze, Improve, and Control.

DMADV stands for Define, Measure, Analyze, Design, and Verify.

Lean Six Sigma is a data-driven approach aiming to reduce unacceptable products or events.

The goal is to achieve a 99.99999% conformance rate, minimizing process variation.

Lean Six Sigma aims to satisfy customers and minimize losses.

Originated from two bodies of knowledge: Lean and Six Sigma.

Lean focuses on waste elimination, introduced by Taiichi Ohno in the 1940s.

Six Sigma emphasizes variation reduction, introduced by Bill Smith and Dr. Michael J. Harry at Motorola in the 1980s.

Combining Lean and Six Sigma methodologies creates a powerful approach for operational excellence.

Lean Six Sigma has a proven track record of helping companies improve processes and achieve significant savings.

The approach is a go-to for companies looking to cut operational costs.

Lean Six Sigma provides a specific problem-solving approach and a set of specialized tools.

The course will teach the high-level approach of the DMAIC methodology.

Lean Six Sigma is deployed as a management system in many companies.

Transcripts

hi let's start our discussion by asking

ourselves what do we know about Lean Six

Sigma you may avert this lens X Sigma

term from course from your college

program or from your workplace talking

about things that are related to price

improvement and problem solving in this

course we will teach you and we will try

to enlighten you about what really is

plain Six Sigma let's start with some

fundamentals Lean Six Sigma can be

defined using the 3m s first metric

second methodology and third management

system Lean Six Sigma is a metric it is

used to measure the capability of a

process to conform to certain

requirements it is known that if a

process follows a Six Sigma level it

only produces three point four defects

per million opportunities as compared to

lower Lean Six Sigma levels like three

sigma or four sigma that produces more

defects per million opportunities by

having that we can conclude that the

higher the Sigma level the better the

process is second Lean Six Sigma is a

methodology it follows a proven and

effective step-by-step process depending

on the type of process that you want to

manage improved or Explorer we have two

non methodologies under the Lean Six

Sigma body of knowledge first we have

the dimeric define measure analyze

improve and control demise is use for

existing processes

the second methodology is the d-mat V

define measure analyze design and verify

this methodology is used for new process

product or services in this yellow belt

course we will teach you on how to use

the high-level approach of the demotic

methodology third definition as

management system Lean Six Sigma has

been deployed by many companies because

of its proven track of record on helping

them improve their processes resulting

to significant amount of savings

therefore this is a go-to approach for

companies if they want the cut costs of

their operations further if you look

into the details of the Lean Six Sigma

as provided in the screen it is set to

be it's a specific problem solving

approach and set of specialized tools to

be able to improve your process and

products we know for a fact that Six

Sigma is data-driven with a goal of

reducing the number of unacceptable

products or events as we talk about Lean

Six Sigma we are also discussing about

how to reduce process variation to a

degree of what we discussed earlier our

three point four defects per million

opportunities or equivalent to a

conformance rate of 99.99999 6 7% the

goal of these initiatives is ultimately

to satisfy the customer and minimize the

losses but before we go into the details

first we must know where does Lean Six

Sigma originated given in the screen you

can see that there are two different

body of knowledge lean and Six Sigma

let's go first to dean lean is waste

elimination we will talk about waste on

the succeeding sections of this course

this has been introduced by taiichi ohno

a technical engineer of Toyota way back

1940s it is said

believe that lien is the practical side

of the combined Lean Six Sigma approach

Six Sigma Six Sigma focuses on variation

reduction this has been introduced by

Bill Smith and dr. Michael J Hardy at

Motorola

weeba 1980s it is said and believed that

Six Sigma is the statistical side of

Lean Six Sigma few decades ago

practitioners have thought of combining

the practical and statistical side of

the two different body of knowledge and

give birth to Lean Six Sigma a

methodology that is more powerful in

driving operational excellence