Introduction to Lean Six Sigma

Question 1

The main aims of Lean are:

Answer 1

1. Eliminate non-value-added (NVA) activities
2. Eliminate the seven types of waste “muda” in industries

Question 2

The seven types of waste “muda” in industries are:

Answer 2

1. motion
2. over production
3. over processing
4. transport
5. inventory
6. waiting time
7. defects

Question 3

Lean tools and techniques are:

Answer 3

1. Kanban system
2. 5S (Sort, Straighten, Shine, Standardise and Self-discipline)
3. Cause and Effect analysis (C&E)
4. Single Minute Exchange of Die (SMED)
5. Value Stream Mapping (VSM)
6. Poka-Yoke
7. Total Productive Maintenance (TPM)
8. Cellular Manufacturing
9. Visual Management and more others

Answer 4

Lean tools and techniques are:
Kanban system
5S (Sort, Straighten, Shine, Standardise and Self-discipline)
Cause and Effect analysis (C&E)
Single Minute Exchange of Die (SMED)
Value Stream Mapping (VSM)
Poka-Yoke
Total Productive Maintenance (TPM)
Cellular Manufacturing
Visual Management and more others

Question 5

Six Sigma Aim

Answer 5

1. Reduce variation in the process
2. Reduce cost in manufacturing and services,
   demonstrate savings to the bottom line,
   increase customer satisfaction
3. Measure defects,
   improve products quality,
   reduce defects to 3.4 parts per million opportunities (DPMO) in an organization

Question 6

Six Sigma uses powerful analytical and statistical tools and techniques such as:

Answer 6

1. Quality Function Deployment (QFD)
2. Failure Mode and Effect Analysis (FMEA)
3. Statistical Process Control (SPC)
4. Design of Experiment (DOE)
5. ANOVA
6. Measurement System Analysis (MSA)
7. Kano Model, etc

Question 7

DMAIC process

Answer 7

1. Define
2. Measure
3. Analyze
4. Improve
5. Control

Question 8

Six Sigma Training

Answer 8

1. Yellow Belts
2. Green Belts
3. Black Belts
4. Master Black Belts
5. Champions

Question 9

Why Six Sigma?

Answer 9

1. Eliminate defects
2. Reduce vartations in process
3. Make saving in bottom line
4. Reduce cost
5. Increase customer satisfaction
6. Improve Quality
7. Use statistical tools

Question 10

Why Lean?

Answer 10

1. Remove waste
2. Improve effecince
3. Improve flow
4. Determine value-added and non-value added activities
5. Use non-statistical tools

Question 11

Why LSS?

Answer 11

1. no waste in process
2. No defects in products
3. low cost
4. increasing in bottom line
5. Icreasing customer satisfaction
6. Increasing employees morale

Question 12

Benefits of LSS:

Answer 12

1. Removing non-value adding activities (waste)
2. Reducing the incidence of defective products/transactions
3. Shortening cycle time and inventory
4. Increase customers satisfaction, attraction and loyalty
5. Reduce cost of production/services
6. Overcoming the limitation of each approach when implemented in isolation

Question 13

Lean Six Sigma Process Improvement Cycle

Answer 13

1. VOICE OF CUSTOMER - Gap Identified
2. STRATEGIC PLAN
3. BUSINESS OBJECTIVES
4. BUSINESS MEASURES
   PROCESS SCORECARD:
5. VALUE STREAM
6. PROCESS FLOW
7. PROCESS MEASURES
8. Control Chart
9. Tools & Methodology (DMAIC)
10. MEASURES again > 3. BUSINESS OBJECTIVES

Question 14

Challenges of LSS

Answer 14

1. Difficulties in teaching statistical methods for some of the team members
2. Time consuming for LSS project implementation
3. Internal resistance
4. Availability of resources such as financial resources, people resources
5. Changing business priorities
6. Lack of leadership, management skills/employees skills , training etc.
7. Poor selection of projects
8. Unmanaged expectations Employee reaction towards a new business strategy
9. National regulation
10. Convincing the top management
11. Lack of awareness about LSS benefits in business

Question 15

Limitations of LSS:

Answer 15

1. LSS has no globally accepted standard for certification
2. No standard framework for LSS or its implementation exists
3. There is no clear direction as to which strategy should be selected at the early stages of a project
4. There is no theoretical underpinning or logical explanation for the choice of methods and techniques
5. The limited number of practical implications of LSS integration framework
6. Lack of real innovation in LSS projects
7. The absence of accurate measurements for LSS implementation
8. Strong LSS curricula are needed in order to leverage learning in organisations

Question 16

Strengths of LSS:

Answer 16

1. Customer focus – the aim of LSS is to build what the customers want as reflected by what is known as CTQ characteristics.
2. LSS combines the right people, right tools and the right projects for its success

Question 17

Weaknesses of LSS:

Answer 17

1. High investment – a significant investment is required to train employees as Yellow Belts, Green Belts, Black Belts and Master Black Belts.
2. Time consuming

Question 18

Opportunities of LSS:

Answer 18

1. LSS approach is applicable in all processes whether it is manufacturing, service or transactional.
2. Implementation of LSS makes a highest quality producer as the lowest cost producer.
3. Integration of LSS with innovation

Question 19

Threats of LSS:

Answer 19

1. Resistance to change
2. Lack of management commitment could be one of the top reasons LSS not taking off in a big way

Question 20

Organizations Implemented LSS in KSA:

Answer 20

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