International Six Sigma Council - Six Sigma Professionals Registration Body

 

 

INTERNATIONAL SIX SIGMA COUNCIL (ISSC)
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Lean Master - Body of Knowledge

Build the Lean Culture

  • Lean Organization Structure
  •  Build Continuous Improvement Teams
    • Create a sense of urgency
    • Team stages and team roles
    • Teamwork, team facilitation and team selection
    • Motivation, empowerment & involvement
    • Setup Skill Sets
      • Skills Assessment
      • On-the-job training
    • Training, Coaching & Mentoring
    • Suggestion System
  • Information Sharing (Yokoten)   
  • Role of a Change Agent
  • Stakeholder Analysis
  • Handling Resistance

Lean Measurement

  • Quality
    • Rework
    • First Pass Yield
  • Delivery
    • Takt Time, Cycle Time and Lead Time
  • Cost
    • Inventory turns
    • Queue Time
    • Wait Time (delays)
    • Overall Equipment Effectiveness (OEE)
    • Changeover Time
  • Financial Impact
    • Hard and soft savings
    • Cash Flow
  • Competitive Impact
    • Customer Satisfaction 

Principles of Lean Improvement

  • Specify Value
  • Process Focus 
  • Identification & Elimination of Barriers to flow
  • 7 Wastes (Muda), Fluctuation (Mura), and Overburden (Muri)
  • Make end-to-end flow visible
  • Manage the flow visually
  • Implement pull
  • Work to perfection

Lean Improvement Systems

  • Lean Improvement Process Methodology - PDCA & DMAIC
  • Quality System - ISO and other standards 
  • A3 storyboards
  • Continuous Improvement (Kaizen)
  • Jidoka
    • Quality at the source
    • No defects passed forward
    • Separate man from machine
    • Multi-porcess handling
    • Self detection of errors to prevent defects
  • From suppliers to customers
    • Lot size reduction
    • Load leveling
    • 3P production process preparation
    • Supplier managed inventory
    • Cross-docking
    • Supplier Assessment and Feedback
    • Supplier Development
    • Warehousing - Planning and Scheduling
  • Benchmarking
  • Reporting
    • Visible feedback real-time

Root Causes Identification Methodologies 

  • Ways to collect Voice of Customer (VOC)
  • Kano Model
  • Translate Voice of Customer (VOC) to Critical to Quality (CTQ)
  • Quality Function Deployment (QFD) 
  • The Gemba Walk 
  • Data Collection and Presentation
    • Histograms, Pareto Charts, Check Sheets
    • Statistical Process Control Charts
    • Scatter and Concentration Diagrams
  • SIPOC, Process Mapping & Value Stream Mapping
  • Spaghetti Diagram and Handoff Map
  • Total Productive Maintenance (TPM) 
  • Cause & Effect Diagrams (Fishbone)
  • 5-whys & 5-hows 
  • Failure Mode and Effects Analysis

Lean Improvement Tools

  • Identifying value added/non-value added work
  • Identify waste
  • Cells, one-piece flow
  • Customer Demand Pace (Takt Time)
  • Mistake proofing (poka-yoke)
  • Pull systems (kanban) & Just in Time (JIT)   
  • Visual Workplace - 5S standards and discipline
  • Standard Work
  • Quick Changeover (SMED)
  • Andon System
  • Supermarket

Theory of Constraints

  • Overview
  • Five Focusing Steps
  • Types of Constraints
  • Drum-Buffer-Rope
  • Logic Trees in Thinking Process

 

 
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