Team Disha OIG

Tools of Lean Six Sigma

Lean six sigma(LSS) is the preferred system by the businesses to streamline, improve, and optimize the
processes end to end. LSS sets itself apart from other techniques by its fusion of improving efficiency by
waste reduction methods from Lean Manufacturing and product/process defect reducing methods of Six
Sigma. The major tools that LSS encompasses are,

1. 5S
2. Kaizen
3. Kanban
4. Poka Yoke
5. Value Stream Mapping(VSM)
6. Just in Time(JIT)

1. 5S Technique:

5S is the way of organizing and managing the workspace and work flow to improve the overall efficiency. It’s
a method of identifying and eliminating waste, improving flow and reducing process variations. 5S activities
creates good working environment through reduction of “Muri”, “Mura”, “Muda”.

Mura: Unevenness, non-uniformity and irregularity. Reason for existence of 7 wastes such as
overproduction, waiting, inventory etc.

1|Page
Team Disha OIG
Muda: Wastefulness, uselessness and futility. All the non-value adding activities that are necessary for the
end customer. Inspection and safety testing does not add direct value to final product but they are necessary
to ensure a safe product for customers.

Muri: Overburden, excessiveness, impossible or unreasonable. Machines or operators are utilized for more
than 100% capability to complete a task.

S1: Sort(Seiri): Removal of all the unnecessary items for the current production. Categorize materials, tools,
files, furniture on the frequency of usage.

1. Need it
2. May need it
3. Do not need it

“Red Tag” the unnecessary items. Free up the valuable floor space(space utilization).

S2: Set(Seiton): Organizing and effective storage of all the necessary items and label them accordingly.

1. Labelling
2. Colour coding
3. Numbering
4. Zoning

Apply “Can see”, “ Can take out” and “Can return” philosophy

S3: Shine(Seiso): Clean and inspect your work area. Create ownership and build pride in workers to maintain
their work area. Cleaning the first level of inspection. Develop and follow regular cleaning and maintenance
schedule.

S4: Standardize(Seiketsu): Write out and follow standards for the above three steps. Make environment
conducive for employees to take up development initiatives. Standardization will lead to equalization of
activities, “Production levelling and smoothing”.

1. Develop work instructions and Standard operating procedures(SOPs)

2. Checklist for regular usage of SOP
3. Colour coding for waste segregation

2|Page
Team Disha OIG
S5: Sustain(Shitsuke): Maintain and follow above four with discipline and commitment. Continual
improvement and periodical reviews of all the 5S activities.

2. Kaizen:
Kaizen is formed by two Japanese words, where “kai” means “change” and “Zen” means “good”. Commonly
known as “Continuous improvement” or “small incremental improvements”. It is distinguished as

1. Flow Kaizen: It deals with reorganization of flow of materials and information.

2. Process Kaizen: Improvement of individual work.

It works by reducing waste(MUDA) and eliminating difficult processes(MURI).

Kaizen – Continuous Improvement Model

Kaizen will yield,

1. Increased productivity

2. Improved quality

3. Better safety

4. Lower costs

5. Improved customer satisfaction

3|Page
Team Disha OIG
3. Kanban:
A Japanese word meaning signboard or billboard. It is a scheduling system used in a relay system to
standardize the flow of parts and improve efficiency. The 3 basic principles,

1. Visualize workflow
2. Limit the amount of work in process
3. Enhance the existing flow

Kanban board is a visualization of the work process. It can be just a white board with sticky notes or virtual
boards accessible through cloud. A Kanban card depicts the work item/task in progress. It represents inventory
status, tasks status, cycle time. Kanban encourages self-management and reduces time spent on meetings.

4. Poka Yoke:
Poka yoke meaning “mistake proofing”, is a mechanism that prevents defects from being made or highlights a
defect so that it does not pass to the next operation. Mistakes are in evitable in processes but defects are
mistakes that manage to get through the system and reach end customer. Poka Yoke prevents mistakes from
becoming defects.

4|Page
Team Disha OIG
Types of Poka Yokes:

Poka Yoke is based on prediction and detection. There are two basic types of poka yoke systems.

1. Contol Poke Yoke:

The control poka yoke does not allow a process to begin or continue after an error has occurred. For example,
a fixture on a machine may be equipped with a sensing device that will not allow the process to continue
unless the part is properly inserted.

2. Warning Poka Yoke:

This poka yoke provides some type of warning when error occurs. This does not prevent the error, but
immediately stops the process when an error is detected. This type of poka-yoke is useful for mass production
environments with rapid processing as the device prevents mass production of scrapped material.

5. Value Stream Mapping:

Value Stream Mapping (VSM) is the process of mapping the material and information flows required to
coordinate the activities performed by manufacturers, suppliers and distributors to deliver products to
customers. VSM is a mapping tool that maps not only material flows but also information flows that signal and
control the material flows. A value stream focuses on areas of a firm that add value to a product or service,
whereas a value chain refers to all of the activities within a company. The purpose of value stream mapping is
to identify and remove or reduce wastes in value streams to increase the efficiency of a given value stream.
Wastes removal is done through these three operations,

1. Non-Value adding operations(NVA): actions that should be eliminated, such as waiting

2. Necessary but not adding value(NNVA): actions that are wasteful but necessary under current operating
procedures.

3. Value adding(VA): Processing of raw materials

5|Page
Team Disha OIG
6. Just in Time(JIT):
Just in time inventory system is a strategy that aligns material orders from suppliers to direct production
schedules. This increases efficiency and decrease waste due to inventory. It heavily depends on efficient
demand forecast.

A list of methodologies of JIT manufacturing are

• Set up reduction: flexible changeover methods

• Single Lot sizes: optimum lot size and flexibility
• Preventive maintenance: Zero stoppages
• Pull system: Kanban supply systems
• Streamlined movements: smooth material handling

Advantages of JIT are

1. Reduced storage costs

2. Reduced set up change over times
3. Improved flow of goods in/through/out ware house
4. Consistency in scheduling and employee work hours
5. Over the clock supplies keeping productivity high
6. Easy product change over

The disadvantages of JIT inventories involve supply chain disruptions. Single supplier can shut down the entire
production process. A sudden order for goods that is more than the expectations may delay delivery of finished
goods.

6|Page