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Implementing Lean Six Sigma in 30 Days

Book Description

Implement the world's most powerful improvement Methodology in 30 Days

  • Plan and manage a successful Lean Six Sigma implementation

  • Develop solutions to problems that undermine quality and inhibit efficiency

  • Get to grips with the world’s most powerful improvement methodology

  • In Detail

    Lean and Six Sigma are two of the most important developments to come out of management theory. On their own they offer clear strategies for improving efficiency and controlling quality; together they are an even more formidable prospect, providing organizations with a strategy that can bring in improvements in both, a task which can sometimes be a real challenge. Gopal Ranjan and Tanmay Vora, experienced in the fields of quality management and passionate about helping organizations drive improvement, present a clear strategy for implementing lean six sigma, giving you both the knowledge and the tools to drive improvement successfully.

    Implementing Lean Six Sigma structures the implementation process over a month, and gives you clear guidance on what to do and when. Beginning with the theoretical basics of Six Sigma, it then takes you through the various stages of a Lean Six Sigma improvement program, from defining and analyzing issues with efficiency and quality, to taking the steps that can get your organization the results it needs. Practical, knowledgeable and accessible, this guide will make Lean Six Sigma your improvement methodology of choice

    How can we improve? This is one of the most fundamental, but challenging, questions an organization can ask itself. It is never easy, but the ability to drive significant change that can bring positive results is immensely important for a business that wants to be successful in a rapidly growing market. Lean Six Sigma offers a way of answering this question, combining the approaches of both Lean and Six Sigma in a way that offers an opportunity for exponential improvement in a way that is manageable, flexible and sustainable. Spanning a month's implementation process, this book will take you on a Lean Six Sigma journey, where you will gain a clear understanding of the fundamental principles, and develop a clear perspective of the process as it unfolds. From defining the problems to be tackled, to their measurement and analysis, this book leads you towards the stage of innovation where you can take steps that ensure and sustain improvements.

    About the Author

    Gopal Ranjan has extensive experience in developing breakthrough improvements and quality management systems. He is a certified Six Sigma Master Black Belt with more than 16 years of experience in the design and deployment of Lean Six Sigma methodology across different organizations. He is also a certified Balanced Scorecard Practitioner. He is also the Lead Auditor on ISO 9001 and ISO 27001 standards. He holds a BTech degree from India's prestigious Indian Institute of Technology, BHU, Varanasi, as well as a Master's degree in Business Administration in Finance. He is also a practicing NLP practitioner and holds a Master's degree in Psychotherapy and Counseling. He regularly writes articles and columns on varied subjects including management, science, psychology, and philosophy for newspapers and magazines. Currently, he heads the Quality function of one of India's foremost IT services companies, Datamatics Global Services Ltd. He can be reached at gopalranjan_2000@yahoo.com.

    Table of Contents

    1. Implementing Lean Six Sigma in 30 Days
      1. Implementing Lean Six Sigma in 30 Days
      2. Credits
      3. About the Authors
      4. About the Reviewers
      5. Preface
        1. What this book covers
        2. Who this book is for
        3. Conventions
        4. Reader feedback
        5. Piracy
      6. 1. What is Lean Six Sigma?
        1. Six Sigma
          1. The key concepts of Six Sigma
            1. Accuracy and precision
            2. Y=f(x)
            3. Focus on defects and variation
            4. Exponential improvement
            5. Three Dimensions
          2. Advantages of Six Sigma
        2. Lean
          1. Key concepts of Lean
            1. Waste
            2. Value and non-value adding activities
            3. Process cycle efficiency
            4. Process velocity
          2. Advantages of Lean
        3. The concept of Lean Six Sigma
        4. Case study
        5. Summary
          1. Quiz
      7. 2. Planning the Implementation
        1. Life cycle of Lean Six Sigma
        2. Initiate (days 1-2)
        3. Enable (days 3-8)
          1. Typical distribution of various belts
        4. Implementing your projects (day 9 onwards)
          1. Green Belt and Black Belt projects
        5. Replicate (ongoing)
        6. Sustain (ongoing)
          1. Project and program review
          2. Communication
        7. Summary
          1. Quiz
      8. 3. Define (Days 9-11)
        1. Project charter (day 9)
        2. Voice of customer (day 10)
        3. High-level process map (day 11)
        4. Form team (day 11)
        5. Checklist
        6. Case study – the Define stage
        7. Summary
          1. Quiz
      9. 4. Measure (Day 12-17)
        1. Key deliverables
        2. Identifying key measures (day 12)
        3. Data collection plan (day 12-14)
          1. Clarification of objectives
          2. Developing operational definitions and procedures
          3. Collect data
          4. Evaluation of sample size
        4. Measurement system analysis (day 15)
        5. Gage R&R
        6. Data representation (day 15)
          1. Pareto diagram
          2. Bar chart
          3. Pie chart
          4. Histogram
          5. Box plot
          6. Multi-vari chart
          7. Run chart
          8. Control chart
        7. A detailed process map (day 15-16)
        8. Baseline performance measurement (day 16-17)
          1. For discrete data
          2. For continuous data
        9. Case study – Measure
        10. Summary
          1. Quiz
      10. 5. Analyze (Day 14-19)
        1. Key deliverables
        2. Identification and prioritization of root causes (day 14-17)
        3. Cause-and-effect diagram (day 14)
        4. Data analysis (day 14-15)
        5. Process analysis (day 16-17)
        6. Hypothesis testing (day 18-19)
          1. Hypothesis testing examples
        7. Case study – analyze
        8. Summary
          1. Quiz
      11. 6. Improve (Days 20-25)
        1. Key deliverables
          1. Generate ideas (days 20-21)
            1. Brain storming
            2. Affinity diagram
            3. Force field analysis
            4. SCAMPER
          2. Select ideas (day 22)
          3. Implement solutions (days 22-24)
            1. Work-breakdown structure (WBS)
            2. Gantt chart
            3. Risk assessment and mitigation
        2. Some Lean manufacturing tools
          1. 5 S
          2. Kaizen
            1. Mistake proofing
          3. Validate solutions (day 25)
        3. Case study – improve
        4. Summary
          1. Quiz
      12. 7. Control (Days 26-30)
        1. Key Deliverables
          1. Process-monitoring plan (days 26-29)
          2. Control charts (days 27-29)
            1. Control charts for continuous data
            2. Control charts for discrete data
          3. Project documentation (day 30)
        2. Case Study – Control
        3. Summary
          1. Quiz
      13. 8. Best Practices and Pitfalls
        1. Best practices
          1. The power of stretch goals
          2. Ready-aim-fire
          3. In God we trust, all others must bring data
          4. Tangible targets linked to financial measures
          5. Variation is the voice of the process
          6. Celebrate achievements
          7. Involve the owner of the process
          8. Project goals should be aligned to organizational goals
        2. Pitfalls
          1. "Our process is so different"
          2. Relying blindly on data
          3. Projects with too large a scope
          4. Needless use of statistics and tools
          5. Part-time Black Belts
          6. Over training
          7. Inflated opportunity counts
          8. Inadequate use of automation or technology
        3. Summary