Lean Six Sigma: Methods for Production Optimization

Preface
Contents
Glossary of Abbreviations
About the Authors
1 Introduction
	1.1	Classification of the Book
	References
2 5S—Seiri, Seiton, Seiso, Seiketsu, Shitsuke
	2.1	Classification of the Method
	2.2	Description of the Method
	2.3	Workshop 1 “Kit Assembly”
		2.3.1	Implementation
			2.3.1.1 First Practice Run
			2.3.1.2 Second Practice Run
		2.3.2	Blank Templates
	References
3 Lean Six Sigma
	3.1	Classification of the Method
	3.2	Description of the Method
		3.2.1	Define Phase
			3.2.1.1 VOC
			3.2.1.2 Project Contract
		3.2.2	Measure Phase
			3.2.2.1 Measurement System Analysis
			3.2.2.2 Process Capability Analysis
			3.2.2.3 Process Capability Indices
			3.2.2.4 Sigma Level
		3.2.3	Analysis
			3.2.3.1 Pareto diagram
		3.2.4	Improve
		3.2.5	Control
	3.3	Workshop 2: “Precision Origami”
		3.3.1	Implementation
		3.3.2	Process Performance Analysis
		3.3.3	Appendix: Suggested Solution and Blank Templates
	3.4	Workshop 3: “Vegetable Cutter”
		3.4.1	Define Phase
		3.4.2	Measure Phase
		3.4.3	Analyze Phase
		3.4.4	Improve Phase
		3.4.5	Control Phase
		3.4.6	Appendix: Proposed Solution and Blank Templates
	3.5	Workshop 4: “Precision Throw”
		3.5.1	Define Phase
		3.5.2	Measure Phase
		3.5.3	Analyze Phase
		3.5.4	Improve Phase
		3.5.5	Control Phase
		3.5.6	Appendix: Suggested Solution and Blank Templates
	3.6	Workshop 5: “Spaghetti Dispenser”
		3.6.1	Define Phase
		3.6.2	Measure Phase
		3.6.3	Analyze Phase
		3.6.4	Improve-Phase
		3.6.5	Control-Phase
		3.6.6	Appendix: Suggested Solution and Blank Templates
	3.7	Workshop 6: “T-Shirt Folding Board”
		3.7.1	Define Phase
		3.7.2	Measure Phase
		3.7.3	Analyze Phase
		3.7.4	Improve Phase
		3.7.5	Control Phase
		3.7.6	Appendix: Proposed Solution and Blank Templates
	References
4 Poka Yoke
	4.1	Classification of the Method
	4.2	Description of the Method
		4.2.1	Detection Mechanism
		4.2.2	Trigger Mechanism
		4.2.3	Regulatory Mechanism
	4.3	Workshop 7: “Reading and Puzzling”
	Appendix: Suggested Solution and Blank Templates
	References
5 SMED
	5.1	Classification of the Method
	5.2	Description of the Method
		5.2.1	Planning Phase
		5.2.2	Do Phase
		5.2.3	Check Phase
		5.2.4	Act Phase
	5.3	Workshop 8: “Coffee Production”
		5.3.1	Implementation
		5.3.2	SMED Analysis
		5.3.3	Solution proposal and blank templates
	References
6 Line Balancing
	6.1	Classification of the Method
	6.2	Description of the Method
		6.2.1	Actual Analysis
			6.2.1.1 Activities
			6.2.1.2 Customer Cycle
			6.2.1.3 OEE – Overall Equipment Effectiveness
			6.2.1.4 Cycle and Takt Time
		6.2.2	Presentation of Analysis Results
			6.2.2.1 Work Distribution Diagram
			6.2.2.2 Operation List
			6.2.2.3 Network Planning Technique
	6.3	Workshop 9: “Aircraft Manufacturing”
		6.3.1	Production Round 1
			6.3.1.1 Execution of the First Production Round
			6.3.1.2 Round 1: Evaluation
			6.3.1.3 Round 1: Waste Analysis
			6.3.1.4 Round 1: Implementing Improvements
		6.3.2	Production Round 2
			6.3.2.1 Execution of the Second Production Round
			6.3.2.2 Round 2: Evaluation
			6.3.2.3 Round 2: Waste Analysis
			6.3.2.4 Round 2: Implementing Improvements
		6.3.3	Production Round 3
			6.3.3.1 Implementation of the third production round
			6.3.3.2 Round 3: Evaluation
		6.3.4	Documenting Improvements
		6.3.5	Blank Templates (Fig. )
	6.4	Workshop 10: “Paper Airplane Production”
		6.4.1	Execution of the First Assembly Round
		6.4.2	Improvement Approaches and Observations
		6.4.3	Blank Templates (Figs.  and )
	References
7 Spaghetti Diagram
	7.1	Classification of the Method
	7.2	Description of the Method
	7.3	Application of the Spaghetti Diagram
	7.4	Advantages and Disadvantages of the Spaghetti Diagram
	7.5	Workshop 11: “Post office”
		7.5.1	Preparation
		7.5.2	Conducting the Workshop
		7.5.3	Solution Proposal and Blank Templates
	References
8 Value Stream Analysis
	8.1	Classification of the Method
	8.2	Description of the Method
		8.2.1	Product Family Formation
		8.2.2	Customer Needs Analysis
		8.2.3	Value Stream Recording
		8.2.4	Potential Analysis
	8.3	Workshop 12: “Mail Dispatch”
		8.3.1	Preparation
		8.3.2	Implementation
		8.3.3	Suggested Solution
	References
9 Kanban
	9.1	Classification of the Method
	9.2	Description of the Methodology
		9.2.1	1-Card System
		9.2.2	2-Card System
		9.2.3	Conditions for a Kanban System
		9.2.4	E-Kanban
		9.2.5	Signal Kanban—Kanban Board
		9.2.6	Visualization in the Kanban System
		9.2.7	Dimensioning
		9.2.8	Summary
	9.3	Workshop 13: “Sticker”
		9.3.1	Preparation
		9.3.2	Implementation
			9.3.2.1 Variant 1
			9.3.2.2 Variant 2
		9.3.3	Task
		9.3.4	Blank Templates (Figs.  and )
	References