Lean Sigma--A Practitioner's Guide

The Practical Guide to Lean Sigma Problem-Solving— Expanded & Updated!

Lean Sigma delivers results—if you use the right tools and techniques. In this thoroughly updated edition, Ian Wedgwood details his proven best-practices from more than sixty successful Six Sigma and Lean deployments in multiple industries, helping you identify and apply the solutions that will work best in your projects.

This expanded edition of Lean Sigma: A Practitioner’s Guide offers detailed guidance on process improvement, standardization, accelerated improvement, and more. Wedgwood helps you identify potential Lean Sigma projects, even in processes without obvious targets. He illuminates fast, effective routes to solving specific business problems, and explains why these solutions work.

Next, he presents detailed “tools roadmaps”: step-by-step instructions showing exactly how and when to use each of these tools:

• 5 Whys

• 5S

• Affinity

• ANOVA

• Box plot

• Capability

• C&E matrix

• Chi-Square

• Concept ideation, design, selection

• Control charts

• Control plan summary

• Core process map

• Critical path analysis

• Customer interviewing

• Customer requirements tree

• Customer surveys

• D-Study

• Demand profiling

• Demand segmentation

• DOE

• Fishbone diagram

• Handoff map

• KPOVs & data

• Load chart

• MSAs

• Multi-Cycle analysis

• Multi-Vari studies

• Murphy’s analysis

• Normality test

• OEE

• Pareto chart

• Process performance mgmt.

• Poka Yoke

• Process board

• Process FMEA

• Process scorecard /dashboard

• Process variables (I/O) map

• Project charter

• Pull systems & Kanban

• Rapid changeover (SMED)

• Regression

• SIPOC

• Spaghetti map

• Standard work instructions

• SPC

• Swimlane map

• Test of equal variance

• Time

• Total productive maintenance

• T-tests

• Value stream map

With this guide, all Green, Black, or Master Black Belts will benefit from decades of Six Sigma and Lean consulting experience.

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Ian Wedgwood, Ph.D., President and CEO of Haelan Group, has more than two decades of experience guiding organizations through change. He has led and facilitated dozens of Lean Sigma deployments in industries as diverse as healthcare, electronics, engineered materials, chemicals, banking, and hospitality, and has trained and mentored numerous executives, Champions, and Belts.

Prior to his consulting career, Ian worked for the global engineering group Invensys PLC facilitating major initiatives. One such initiative, building a new 180,000 square foot manufacturing facility in Tijuana, Mexico, brought Ian to the United States where he still lives with his wife, Veronica, and sons Christian and Sean. Ian also led Invensys’ highly successful Lean Design for Six Sigma deployment. Some 380+ Design Belts within a single division yielded a 65 times return in less than two years.

Ian holds a Ph.D. and a First-Class Honors degree in Applied Mathematics from Scotland’s St. Andrew’s University. In addition to his consulting work, Ian serves on the faculty of the Jones Graduate School of Business at Rice University.

He also authored Lean Sigma: Rebuilding Capability in Healthcare, shaping how healthcare leaders think about Lean Sigma and its application to this industry in need.

Chapter 1: Introduction

PART I PROJECT ROADMAPS TO SOLVE BUSINESS PROBLEMS
Chapter 2 Define—Tools Roadmap Applied to the Beginning of All Projects
Chapter 3 Global Process Problems
Chapter 4  Individual Step Process Problems
Chapter 5 Control—Tools Used at the End of All Projects 107

PART II ROADMAPS TO FIND PROJECTS WHERE NO OBVIOUS CANDIDATES EXIST
Chapter 6 Discovery—Tools Applied to Identify Projects

PART III Roadmaps to standardize a process

PART IV ROADMAPS TO GUIDE IN THE PRACTICAL APPLICATION OF EACH LEAN SIGMA TOOL
Chapter 7  Tools

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The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.