Quick summary of  the most basic LM ‘tools’ to get you off to a good start.

They include:

• 5S
  • Sort, Set in order, Shine, Standardize, sustain
  • helps organize what’s needed and eliminate what’s not, allowing the organization to identify problems quickly
• 5 Whys
  • Problem-solving by asking why the problem occurred, then why that cause occurred repeating the process five times until you get to the main or ‘root’ cause of a problem.
• Andon
  • operator pulls a cord that triggers a horn and light, which tells the team leader or supervisor that he or she needs help or support.
  • Keep production moving and catching problems early
• Jidoka
  • Autonomation ( Automation with a human touch) or people identifying problems either stopping for correction or self-correcting PRIOR to proceeding or moving on to the next step.
• Kaizen
  • A structured ongoing process  engage those closest to the process
  • improve both the effectiveness and efficiency of the process
  • remove waste and add standardization.
• Kanban
  • A signal or card system that a downstream (customer) process can use
  • Optimized to request a specific amount of a specific part from the upstream (supply) process.
• SMED
  • Single-minute exchange of die
• Visual management
  • manage every aspect of the process at a glance, using visual data, signals and guides.

WE all should pause and take a minute to consider how LM principles, rules, tools and thinking can help us in eliminating waste.

Getting to root-causes makes problem-solving easier and  more permanent! This process is on-going and will reveal things about your business you did not even know at all!

You might be surprised by what you find, unearth and reveal when using LM thinking and tools. Looking at processes to see how to BEST eliminate the different forms of MUDA or waste,  requires new,  counterintuitive thinking at times,  a true non-traditionalist point of view.

Aspects that could get some attention could include things like:

• inventory
• movement/motion
• waiting or queues
• broken equipment, machines or tools (missing)
• unorganized mess, dirt and clutter
• … and many others

Things that we can see that are obvious waste or inefficiencies attract attention and demand action.

This is where lean manufacturing steps in and makes a difference. It deals with the problems that we can actually SEE and do something about.

True to its Japanese origin there are lots of ‘legacy’ terminology here, one of which is MOST appropriate as we start this discussion on lean tools and the implications for your business: It is referred to as MUDA, essentially meaning WASTE.

In any process and business there are EIGHT forms of MUDA/WASTE present:

1. Wasted human potential (The 8th Waste)
2. DEFECTIVE products or flawed services(mistakes)
3. Making too much of something (overproduction)
4. Inventory
5. Unecessary processing (non-value added steps)
6. Unnecessary movement of people (Motion)
7. Unnecessary movement of things (Transportation)
8. Waiting or queuing

When you focus on any improvements for production and profit you will have to pay attention to the saying ‘time is money’ and ‘quality matters’. These two principles and fundamental pillars for lean manufacturing and Six Sigma will reward you greatly if considered in all aspects and areas of your business.

Who Can Obtain Lean Six Sigma Certification?
Anyone who has a real-world experience with practices of  BPM, BPR, TQM, TOC, Lean or six sigma principles will be able to complete the course material. The typical courses are self-directed, with limited remote support. Classroom instruction is available and usually best served for in-house training within one company.

What Are There Prerequisites?

The only prerequisite is the ability to apply the training material to a real-world case and demonstrate ability to apply the principles.

Where Can I Get   Online Lean Six Sigma Certification?
More and more courses are coming online every month as demand increases for lean-six-sigma experts.  Read this review of the 9 key factors for certification options.