1st Edition
Lean Six Sigma A DMAIC Roadmap and Tools for Successful Improvements Implementation
This book is a comprehensive guide that equips organizations and individuals with the necessary tools and knowledge to streamline operations, optimize resources, and deliver superior customer value through implementing lean Six Sigma methodologies. It provides a practical roadmap for achieving process, product, and service improvement. The book introduces readers to the powerful framework of Lean Six Sigma, combining Lean and Six Sigma methodologies. It takes readers through the DMAIC model – Define, Measure, Analyze, Improve, and Control – providing a structured approach to identifying inefficiencies, reducing defects, and enhancing overall business performance. It covers essential topics such as lean Six Sigma leadership, change management, project management, and a detailed explanation of each phase of the DMAIC process.
This book is designed to cater to a diverse audience, including executives, managers, quality professionals, improvement professionals, engineers, operations professionals, customer service professionals, and students. The book offers practical knowledge, tools, and case studies to drive transformative change and build a sustainable competitive advantage.
Table of Contents
List of Figures
List of Tables
Introduction
About the Author
CHAPTER 1 - Introduction to Lean Six Sigma
What is Lean?
Value Chain
Lean Flow
Benefits of a Lean System
What is Six Sigma?
Benefits of Six Sigma
Value of Lean Six Sigma
The DMAIC Model
DMAIC Tollgate Reviews
Lean Six Sigma Roles & Responsibilities
Lean Six Sigma Leadership, Culture, and Change Management
Lean Six Sigma Leadership
Change Management and Building a Lean Six Sigma Culture
Strategies for Rolling out an Improvement Program
Organizational Drivers, Goals, and Metrics
CHAPTER 2 – Projects Management Basics
What is Considered a Project?
Characteristics of Good Improvement Projects
SMART Goals or Objectives
Identify Improvement Projects
Evaluate and Select Improvement Projects
Benefit to Difficulty Ratio (BDR)
Metrics
Project Metrics
Project Planning Tools
Work Breakdown Structure (WBS)
Tree Diagrams
Critical Path Method (CPM)
Process Decision Program Chart (PDPC)
Dashboards
CHAPTER 3 – DEFINE Phase
Overview
Problem Statement
Business Case
Goal Statement
Project Scope
Milestones Plan
The Core Team
SIPOC Diagram
Stakeholder Analysis
Voice of the Customer, Business, and Process
Critical to the Customer Characteristics
Process Owner Involvement
Responsibility Assignment Matrix (RACI)
Team Dynamics
Communication Methods
Risk Analysis
Project Charter
Define Phase Checklist and Tollgate Review
CHAPTER 4 – MEASURE Phase
Overview
Metrics and KPIs
Operational Definitions
Lean Measures
Overall Equipment Effectiveness (OEE)
Descriptive Statistics
Process Variation
Six Sigma Measures
Measurement System Analysis (MSA)
Data Types and Measurement Scales
Data Collection
Check Sheets
Sampling
Sampling Strategies
Sampling Frequency
Sample Size
Time Studies
Cost of Quality (COQ)
Process Mapping and Documentation
Process Mapping Symbols
Basic Flow Charts
Swim Lanes (SL) Flowchart
Detailed Flowcharts
SIPOC Diagram
Value Stream Map (VSM) – Current State
Benefits of Value Stream Mapping
Tips for Creating a Value Stream Map,
Select a Product Family
Value Stream Symbols
Creating a Value Stream Map
Business Case Validation
Measure Phase Checklist and Tollgate Review
CHAPTER 5 – ANALYZE Phase
Overview
Process and Value Analysis
Eight Wastes of Lean
Muda Walk
Opportunity Process Map (OPM)
Yamazumi Chart
Time Value Map (TVM)
Spaghetti Diagram
Graphical Analysis Tools
Run Charts
Scatter Plot
Frequency Chart
Histogram
Cumulative Frequency Distribution
Pareto Charts
Multi-Vari Studies
Correlation
Regression Analysis
Theory of Constraints (TOC)
Statistical Distributions
Normal Distribution
Central Limit Theorem (CLT)
t-Distribution
Poisson Distribution
Binomial Distribution
Bi-Modal Distribution
Skewed Distributions
Statistical Analysis
Hypothesis Testing
Confidence Intervals
p-Value
p-Value vs. Significance Level (□□)
Power of the test
Statistical and Practical Significance 219
1-Sample t-Test (Compare Means)
Standard Error of the Mean (SE Mean)
2-Sample t-Test (Compare Means)
Paired t-Test (Compare Means)
Normality Test
Brainstorming
Root Cause Analysis (RCA)
Understanding the Cause-and-Effect Principle
Action versus Condition Causes
Root Cause versus Direct Cause
5Whys
Fishbone Diagram
Fault Tree Analysis (FTA)
Occurrence vs. Detection vs. Systematic Causes
Analyze Phase Checklist and Tollgate Review
CHAPTER 6 – IMPROVE Phase
Overview
Generate Improvement Ideas
Nominal Group Technique (NGT)
Round-robin Brainstorming
Brain-writing
Electronic Brainstorming
Mind Mapping
Assumption Busting
Benchmarking
Categorize and Prioritize Ideas
Benefit to Difficulty Ratio (BDR)
Affinity Diagram
Force Field Analysis (FFA)
Multi-Voting
Pugh Matrix
PICK Chart
Pilot Improvements
Design of Experiments (DOE)
Simulation
Implement Improvements
5S (Workplace Organization)
Kaizen Events
Single Minute Exchange of Dies (SMED)
Poke Yoke (Mistake Proofing)
Jidoka and Andon
Waste Elimination
Create Lean Flow
Push Manufacturing
Batch and Queue (B&Q)
Just-in-Time (JIT)
Kanban System
Reorder Point
Pull Connections
Continuous Flow (CF)
Sequential Pull (FIFO Lanes)
Replenishment Pull (Supermarkets)
A Two-Bin Supermarket
FIFO Lane and Supermarket Combinations
CONWIP System
Pacemaker Process
Production Leveling (Heijunka)
Cycle Time and Lead Time Reduction
Failure Mode & Effect Analysis (FMEA)
Improve Phase Checklist and Tollgate Review
CHAPTER 7 – CONTROL Phase
Overview
Standard Work (SW)
One Point Lessons (OPL)
Visual Workplace
Process Monitoring
KPIs and Process Metrics
Control Charts
Stability Analysis Rules: Tests for special causes
X̅-R (X Bar R) Chart
X̅-S (X Bar S) Chart
np Chart
p Chart
c Chart
u Chart
Control Plans
Sustainability Audits
Project Documentation
Verify Improvement Impact
Lessons learned!
Future Improvements
Project Closure
Control Phase Checklist and Tollgate Review
Appendix A: z table, Cumulative Standard Normal
Appendix B - Acronyms
Appendix C - Glossary
Index
Biography
Dr. Mohammad Al-Rifai holds a Ph.D. in Industrial Engineering from the University of Arkansas and a Bachelor's and Master's in Mechanical Engineering from Jordan University of Science and Technology. He has a wealth of experience in Lean Systems and Six Sigma, having earned various certifications over the years. He received his first professional lean manufacturing training in 2005 and earned his Lean Systems Operation Excellence Champion Certification from the Institute for Lean Systems in 2008. In 2007, he also received his Six Sigma Green Belt from the Institute of Industrial Engineers. In 2009, he became a Certified Six Sigma Black Belt (ASQ CSSBB) by the American Society for Quality. In 2018, he achieved the status of Certified Six Sigma Master Black Belt (ASQ MMB) by the American Society for Quality.
With almost two decades of experience working for large U.S. companies across various industries, Dr. Al-Rifai has an impressive track record of deploying strategic plans to support business growth, improve efficiency, and reduce costs. He is an expert in organizational culture transformation, process improvement, operational excellence, strategic planning, project management, training, staff development, and operations management. He has also trained thousands of Lean Six Sigma champions, helping companies develop continuous improvement initiatives to achieve their goals.
