1. Guide to Business Improvement Tools
LEAN MANUFACTURING
&
SIX SIGMA

2. Contents Overview of LEAN Manufacturing Overview of Six Sigma
PDCA Wheel
Six Sigma Roadmap
Tool selection guide

3. LEAN Manufacturing
Henry Ford production line to Toyota Production System
Methodology spread across industries and countries
Production activity that is not important to the customer is seen as waste, and to be reduced / eliminated.
Focuses on optimising ‘production flow’ .
Converts ‘push through to sell’ production to ‘pull through by customer demand’ production.

4. PDCA Wheel
A foundation tool of LEAN to explain to teams how to make process improvements.
Plan the improvement
Do the trial
Check the results
Action the new standard
Once the new standard is locked in, further improvement activity can occur

5. Six Sigma ( 6σ )
Created by Motorola in the 1970’s in response to quality criticisms
Heavy on Statistical Process Control and Hypothesis testing
Focus is to reduce defects by reducing process variability
Quality side tools
Acceptance side tools
A 6σ process is % accurate
(Between three and four defects per million opportunities)
Excellence = Quality x Acceptance

6. Six Sigma DMAIC Roadmap
Define
Measure
Analyse
Improve
Control
A. Project Blitzed
added to
BCS
Pipeline 1
Business Case and draft Charter into Project Pipeline in BCS 5
Validate Measurement System 13
Identify & Select Potential Solutions 8
Develop data collection plan around key x’s; 12
Practically
validate root causes 11
Graphically & Statistically validate root causes 9
Implement & Control
Quick Wins 16
Demonstrate final capability and control plan effectiveness $ 2
Project Selected and
Project Leadership Team Selected
I -1
Stakeholder check-in 
Q-A Solutions Approved 6
Confirm Current Process Performance 10
Collect data around key x’s 17
Final sign off by Process Owner $
B. Project Kickoff
Move to Investigation Phase 14
Develop Implementation Plan, Control Plans and process control system
Project Completed 3
Check and Learn from previous work 7
Identify key x’s
&
Quick wins
Start
Project
Cycle time
End Project
Cycle time 18
Share
Learnings;
Replication ,
Report, Poster $
I -2
Stakeholder check-in 
Implementation Approved 4
Align Team & confirm Project Charter 19
Celebrate Improvements and Recognise Team $
C. End Investigation Cycle time
Cycle time 1 D
Stakeholder check-in 
Charter Confirmed M
Stakeholder check-in  A
Stakeholder check-in  15
Implement Approved Solution(s) and Control Plans
Belt PO
PL or Mgmt
Primary Responsibility of
Rev v10 A
Required Financial review (BCS entry) $

7. Six Sigma / Lean Define Measure Analyse Improve Control
Desired Outcomes
Six Sigma
Tools to Use
Lean
Tools to Use
Define
Confirmed Charter
Mobilised Team
Engaged Stakeholders
ACtE, VOC, CTQ, SIPOC, In/Out, Project Charters
Project Chartering, Value Stream, Theory Of Constraints, Yield, Rolled Throughput Yield
Measure
Process Characterised
Data Validated
Capability Analysis on Y output
ACtE, MSA,XY, FMEA, Process Map, Data Collection Plan
Interview & Observation, 5S, Time & Motion, VSM VA / NVA, Flow Charting, Base Line Analysis, Spaghetti Diagrams.
Analyse
Uncover Root Causes
ACtE, Hypotheses testing, Multi Vari, Control Charts, FMEA
Takt Time, Multi Cycle Analysis, Root Cause ID, Defect Analysis
Improve
Solutions Selected
Implementation Plan
Committed Stakeholders
ACtE, DOE, BOA, Training, Change Mgmt
SMED, Quick Changeover, Load Balancing, Kanbans, Simulation
Multiskilling, Mistake Proofing
Control
Transition to Owner
Process Control System
Knowledge Sharing
ACtE, Control Plans, SOP, SPC, Control Charts, Action Plans
5 S Discipline, Standard Work, On time delivery, Perform to Takt Time
Aligning Commitment towards Excellence (ACtE) supports all stages of the process!