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Lean Six Sigma

Book Description

The Breakthrough Program for Increasing Quality, Shortening Cycle Times, and Creating Shareholder Value In Every Area of Your Organization Time and quality are the two most important metrics in improving any company's production and profit performance. Lean Six Sigma explains how to impact your company's performance in each, by combining the strength of today's two most important initiatives--Lean Production and Six Sigma--into one integrated program.

The first book to provide a step-by-step roadmap for profiting from the best elements of Lean and Six Sigma, this breakthrough volume will show you how to:

  • Achieve major cost and lead time reductions this year

  • Compress order-to-delivery cycle times

  • Battle process variation and waste throughout your organization

Separately, Lean Production and Six Sigma have changed the face of the manufacturing business. Together, they become an unprecedented tool for improving product and process quality, production efficiency, and across-the-board profitability. Lean Six Sigma introduces you to today's most dynamic program for streamlining the performance of both your production department and your back office, and providing you with the cost reduction and quality improvements you need to stay one step ahead of your competitors.

"Lean Six Sigma shows how Lean and Six Sigma methods complement and reinforce each other. If also provides a detailed roadmap of implementation so you can start seeing significant returns in less than a year."--From the Preface

Businesses fundamentally exist to provide returns to their stakeholders. Lean Six Sigma outlines a program for combining the synergies of these two initiatives to provide your organization with greater speed, less process variation, and more bottom-line impact than ever before.

A hands-on guidebook for integrating the production efficiencies of the Lean Enterprise with the cost and quality tools of Six Sigma, this breakthrough book features detailed insights on:

  • The Lean Six Sigma Value Proposition--How combining Lean and Six Sigma provides unmatched potential for improving shareholder value

  • The Lean Six Sigma Implementation Process--How to prepare your organization for a seamless incorporation of Lean Six Sigma tools and techniques

  • Leveraging Lean Six Sigma--Strategies for extending Lean Six Sigma's reach within and beyond your corporate walls

"Variation is evil."--Jack Welch

Six Sigma was the zero-variation quality lynchpin around which Jack Welch transformed GE into one of the world's most efficient--and valuable--corporations. Lean Production helped Toyota cut waste, slash costs, and substantially improve resource utilization and cycle times. Yet, as both would admit, there was still room for improvement.

Lean Six Sigma takes you to the next level of improvement, one that for the first time unites product and process excellence with the goal of enhancing shareholder value creation. Providing insights into the application of Lean Six Sigma to both the manufacturing processes and the less-data-rich service and transactional processes, it promises to revolutionize the performance efficiencies in virtually every area of your organization--as it positively and dramatically impacts your shareholder value.

Table of Contents

  1. Cover Page
  2. Lean Six Sigma
  3. Copyright Page
  4. Contents
  5. Preface
  6. Part One. The Lean Six Sigma Value Proposition
    1. 1. Lean Six Sigma: Creating Breakthrough Profit Performance
      1. The Roadmap to Higher Shareholder Value
      2. The Lean Six Sigma Secret
      3. The Lean Six Sigma Value Proposition
      4. Lean Six Sigma and MRP
      5. The Power Is in the Total Process
      6. To Learn More
    2. 2. Six Sigma: The Power of Culture
      1. Critical Success Factors for Six Sigma
      2. Predicting Team Success, Preventing Team Failure
      3. The Six Sigma Process and Improvement Tools
      4. The Role of Six Sigma as a Metric
      5. The Key Is in the Culture
      6. Key Messages of Six Sigma
      7. To Learn More
    3. 3. Lean Means Speed
      1. Is This Lean?
      2. The Essentials of Lean
      3. The Lean Metric: Cycle Efficiency
      4. Velocity of Any Process
      5. Knowing Where to Focus: The 80/20 Rule
      6. Using a Value Stream Map to Find the 20% Waste
      7. The Major Lean Improvement Tools
      8. The Lean Enterprise
      9. Epilogue on Ford
      10. The Laws of Lean Six Sigma
      11. To Learn More
    4. 4. Creating Competitive Advantage with Lean Six Sigma
      1. The Need for Executive Engagement
      2. Value Stream Selection à la Warren Buffett
      3. Competing with Lean Six Sigma
  7. Part Two. The Lean Six Sigma Implementation Process
    1. 5. Initiation: Getting Commitment from Top Management
      1. Laying the Groundwork
      2. Leadership Engagement
      3. The Next Moves
    2. 6. Infrastructure and Deployment Planning
      1. Plan Components and Typical Timelines
      2. The Detailed Deployment Plan
      3. A. Process Focus
      4. B. Organizational Structures
      5. C. Measures
      6. D. Rewards and Recognition
      7. E. Infrastructure Tools
      8. Completing the Deployment Plan
    3. 7. Kickoff: Establishing the Vision Company-Wide
      1. Structure of the Transforming Event
      2. A. CEO Presentation
      3. B. Design Team Presentation
      4. C. "Testimonials" from Experienced Companies
      5. D. Simulation
      6. E. Launch Preparations
      7. The Cascade of Transforming Events
      8. Achieving a Company-Wide Vision
      9. Only the Beginning …
    4. 8. Selecting the Right People—and the Right Projects
      1. Selecting Black Belt Resources
      2. Selecting Projects
      3. The Language of Project Selection
      4. Who Does What
      5. Diagnostic Processes for Project Identification
      6. Top-Down Project Identification
      7. Bottom-Up Project Identification
      8. Grouping and Screening Ideas
      9. Project Definition and Scoping
      10. Final Project Selections
      11. Projects Suitable for Lean Six Sigma
      12. Selecting the Right Resources and Projects
    5. 9. Predicting and Improving Team Performance
      1. Understanding Individual Performance
      2. Preferred Team Roles as Predictors of Team Success or Failure
      3. Applying Belbin's Research
      4. The Importance of Team Leadership
      5. Implications for Black Belt Training
    6. 10. Implementation: The DMAIC Improvement Process
      1. The Context of Improvement
      2. The DMAIC Process and Its Tools
      3. A Walk Through DMAIC
      4. Developing Focus: The DMAIC Filter
      5. Big Gains with Simple Tools: Two Examples
      6. Implications for Black Belt Training
    7. 11. Implementation: The DMAIC Tools
      1. Define Tools
      2. Measure Tools
      3. Analyze Tools
      4. Improve Tools
      5. Control Tools
      6. Using the Lean Six Sigma Tools
    8. 12. Institutionalizing Lean Six Sigma
      1. Institutionalization
      2. Planning for Each Business Unit Launch
      3. The Executive's Role
      4. Emphasizing the Ultimate Goals
  8. Part Three. Leveraging Lean Six Sigma
    1. 13. Total Supply Chain Acceleration
      1. Part A: Accelerating Your Internal Supply Chain
      2. Part B: Extending the Enterprise to Suppliers
      3. Part C: The Downstream Pull System
    2. 14. Lean Six Sigma Logistics
      1. Inventory and Strategic Goals
      2. Inventory and The Cost of Production
      3. Fundamental Logistics Cost Drivers
      4. Lean Manufacturing, Raw Materials, and Inventory Management
      5. Implementing Lean Logistics
      6. Challenges of Lean Logistics
    3. 15. Design for Lean Six Sigma
      1. The Case for Applying Lean Six Sigma to the Design Process
      2. Improving Design Velocity
      3. Design for Lean Six Sigma
      4. Final Thoughts on Lean Six Sigma and Product Development
  9. Index