Lean Six Sigma for Small and Medium Sized Enterprises: A Practical Guide

It is no secret that Lean Six Sigma (LSS) is not as popular with small and medium-sized enterprises (SMEs) as it is with larger ones. However, many SMEs are suppliers to larger entities who are pushing for superior quality and world-class process efficiencies from suppliers.

Lean Six Sigma for Small and Medium Sized Enterprises: A Practical Guideprovides a roadmap for the successful implementation and deployment of LSS in SMEs. It includes six real-world case studies that demonstrate how LSS tools have been successfully integrated into LSS methodology. Simplifying the terminology and methodology of LSS, this book makes the implementation process accessible.

• Supplies a general introduction to continuous improvement initiatives in SMEs
• Identifies the key phases in the introduction and development of LSS initiatives within an SME
• Details the most powerful LSS tools and techniques that can be used in an SME environment
• Provides tips on how to make the project selection process more successful

This book covers the fundamental challenges and common pitfalls that can be avoided with successful introduction and deployment of LSS in the context of SMEs. Systematically guiding you through the application of the Six Sigma methodology for problem solving, the book devotes separate chapters to the most appropriate tools and techniques that can be useful in each stage of the methodology.

Keeping the required math and statistics to a minimum, this practical guide will help you to deploy LSS as your prime methodology for achieving and sustaining world-class efficiency and effectiveness of critical business processes.

Table of Contents

Introduction to Small and Medium-Sized Enterprises (SMEs) 
Introduction
Definition of SMEs
SMEs’ Contribution to World Economy
Characteristics of SMEs
SMEs versus Larger Firms
Summary
References

Continuous Improvement Initiatives in SMEs
What is Continuous Improvement?
Continuous Improvement Practices in Small and Medium-Sized Enterprises (SMEs)
Critical Success Factors in the Implementation of CI Practices in SMEs
Leadership for CI
Sustainability of CI Initiatives
Summary
References

Lean Six Sigma
What is Lean Production System?
Key Principles of Lean Production System
Benefits of Lean Production System
What is Six Sigma?
Some Common Myths of Six Sigma
An Overview of Six Sigma Methodology
Benefits of Six Sigma
Some Pros and Cons of Lean and Six Sigma
Why Lean Six Sigma?
Benefits of Lean Six Sigma
Challenges in the Implementation of Lean Six Sigma
Summary
References

Lean Six Sigma Road Map for SMEs
Readiness Factors for the Successful Introduction of LSS
Lean Six Sigma Implementation Infrastructure
A Road Map for Implementing Lean Six Sigma
Managerial Implications
Summary
References

Lean and Six Sigma Metrics
Introduction
Introduction to Common Metrics of Lean
Introduction to Common Metrics of Six Sigma
Lean Six Sigma Metrics
Overall Equipment Effectiveness
Summary
References

Six Sigma Methodology
Introduction
Define Phase
Measure Phase
Analyze Phase
Improve Phase
Control Phase
Summary
References

Basic and Advanced Tools of Lean and Six Sigma for SMEs
Suppliers, Inputs, Process, Outputs and Customer
Value Stream Mapping
5S Practice
Single Minute Exchange of Dies
Visual Management
Standard Operating Procedures
Cause and Effect Analysis
Pareto Analysis
Histogram
Scatter Diagram and Correlation Analysis
Control Charts
Run Charts
Failure Modes and Effects Analysis
Voice of the Customer Analysis
CTQs and a CTQ Tree
Project Charter
Hypothesis Tests
Regression Analysis
Kanban System
Poka-Yoke (mistake proofing)
Root Cause Analysis or 5 Whys Analysis
Design of Experiments
Process Mapping
Measurement System Analysis
Solution Selection Matrix
Summary
References

LSS Project Selection
What is an LSS project?
Project Selection and Prioritization
Management of Project Reviews
Some Tips for Making Your LSS Projects Successful
Summary
References

Industrial Case Studies of Lean Six Sigma
Case Study 1: Application of Six Sigma Methodology in a Small-Scale Foundry Industry
Case Study 2: Application of Six Sigma Methodology in Road Construction for Wind Turbine Installation
Case Study 3: Application of Six Sigma Methodology to Reduce the Rejection and Rework in an Automobile Supplier Company
Case Study 4: Application of Value Stream Mapping in a Camshaft Manufacturing Organization
Case Study 5: An Application of Lean Six Sigma to a Die Casting Process

References

Index

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