Certified Lean Six Sigma White Belt Exam Prep

a. Introduction to Lean

Lean originated as an offspring of the manufacturing industry, particularly from the Toyota Production System (TPS) established after World War II. It aims to maximize value for customers in an effort to eradicate waste. It promotes processes that are continually enhanced in terms of efficiency. It emphasizes offering value in less difficult processes.

b. What is Lean, Six Sigma, and Lean Six Sigma?

Lean: A methodology of waste removal and process enhancement.

Six Sigma: A data-driven approach focused on reducing defects and variability in processes with statistics

Lean Six Sigma: This is a hybrid methodology that combines the focus of the Lean method towards waste elimination with the emphasis of Six Sigma on quality improvements. It aims at being efficient and effective in the processes.

c. Key 7 Principles of Lean Six Sigma

Define Value: Understanding what adds value from the customer's perspective.

Value Stream Mapping: All the steps involved in a process are to be identified and mapped in order to find waste

Flow: No blockages should be given in the flow of processes

Pull: Only when and what is required should be produced

Perfection: Each improvement should be able to eliminate waste

Engagement: Involvement of everybody in the organization for improvements in the process

Measure: This will use the metrics to measure their performance and the progress

d. Understand Process, Waste (with 8 Types of Wastes), and Variation

Process: A series of activities performed to achieve an objective.

Waste: Any activity that consumes resources and adds no value. The 8 wastes (these are often abbreviated as TIMWOOD) are

Transportation: Ineffective movement of goods or products.

Inventory: Products that are sitting in inventory and not processed

Motion: Ineffective people movement

Waiting: Time is spent waiting for the next step in a process

Overproduction: More is produced than what is needed.

Overprocessing: More is done than necessary .

Defects : Work created by rework, scrap, and bad information.

Unused Talent: Poor use of worker skills and abilities.

Variation: A part of a process that can lead to defects or waste

e. Problem-Solving using PDCA Cycle

The PDCA cycle, or Plan-Do-Check-Act, is a problem-solving tool.

Plan: Define the problem and research it then work out a course of action.

Do: Carry out the course of action on a small scale.

Check: Measure the results and decide if the plan worked.

Act: If it does work then scale the solution; if not, revise the plan.

f. Lean Framework

Standardization and 5S: 5S (Sort, Set in order, Shine, Standardize, Sustain) keeps a neat workplace.

Just-In-Time (JIT): Producing only what is needed, at the right time. Key ideas include:

Takt Time : The greatest permissible time that could be taken to make an item to fulfill customer demand.

Single Piece Flow: Process one at a time at a pace to ensure efficiency.

Pull vs Push Systems: A pull system builds according to demand, and a push system builds according to forecast.

Built-In Quality: Quality is assured at every step of the process

Managing for Daily Improvements: Engage employees in seeking and implementing daily improvements.

g. DMAIC Framework for Process Improvement

DMAIC (Define, Measure, Analyze, Improve, Control) is a structured problem-solving methodology used in Lean Six Sigma:

Define: The definition of the problem and project objectives.

Measure: Data collection and measurement of the current situation

Analyze: Root causes of defects and problems.

Improve: Develop solutions to counter the root causes.

Control: Control measures to sustain improvements.

h. Japanese Terms in Lean

Kaizen: Continuous improvement.

Muda: Waste.

Kanban: A visual system for managing work.

Gemba: The real place where work is done.

Jidoka: Automation with a human touch, with focus on quality control.

i. To Strive for Perfection

Lean Six Sigma fosters relentless striving for excellence through continuous improvement with the objective of waste reduction and defects minimization towards higher customer satisfaction.

j. Different Levels of Lean Six Sigma (Belt Levels)

White Belt: Familiarized with the basics of Lean Six Sigma

Yellow Belt: Familiarized with the fundamentals, involved in smaller improvement initiatives

Green Belt: Lead small-scale initiatives and assist large-scale initiatives.

Black Belt: Master of Lean Six Sigma methods, projects, and mentoring.

Master Black Belt: An experienced person who has a strategic mindset, implementing training inside the organization.