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COURSE TITLE: Productivity & Quality Management

SUBMITTED TO : Sir Doctor Jamil Ahmad

SUBMITTED BY: Muhammad Junaid Hanif

Registration No: FA15-BCS-132

Due Date: 15/04/2019

Lean Six Sigma Technique

Lean is popular for its methodical approach to streamlining both manufacturing and service
processes by eliminating waste while continuing to deliver value to customers.
Six Sigma is a systematic approach for eliminating errors. Six Sigma uses statistical methods to
improve quality by minimizing variability in business processes, from manufacturing to
engineering and purchasing.
Lean Six Sigma is a combination of two powerful process improvement methods: Lean and Six
Sigma. Lean Six Sigma is a method that relies on a collaborative team effort to improve
performance by systematically removing waste and reducing variation. It combines lean
manufacturing/lean enterprise and Six Sigma to eliminate the eight kinds of waste.
 Defects
 Over-Production
 Waiting
 Non-Utilized Talent
 Transportation
 Inventory
 Motion
 Extra-Processing

Lean six sigma not only reduces process defects and waste, but also provides a framework for
overall organizational culture change
Five Key Six Sigma Principles
Six Sigma success is based on five key principles:

 Focusing on customer requirements

 Using extensive measurement and statistical analysis to understand how work gets done
and to identify the root cause of problems (variations)
 Being proactive in eliminating variation and continually improving the process
 Involving people in Six Sigma cross-functional teams
 Being thorough and being flexible

How does Lean Six Sigma work?

Lean Six Sigma is simply an effective methodology used to fix a problem. Six Sigma
accomplishes its goal by using two Six Sigma Methods: DMAIC and DMADV.

Six Sigma DMAIC

The Six Sigma DMAIC approach is typically used to improve an existing process. DMAIC is an
acronym that stands for:

 Define the problem and desired outcome

 Measure the ability of the process
 Analyze the data and identify the root cause of variations (defects)
 Improve or modify the process so that fewer variations (defects) are produced
 Control the process. Prevent and correct variations before they result in defects
Six Sigma DMADV
When designing a new process, the Six Sigma DMADV is used. It is also known as DFSS
(Design for Six Sigma). The DMADV acronym stands for:

 Define design standards that align with the product or process goals
 Measure and identify characteristics of the product or process that are critical to quality
 Analyze the data, and identify possible sources of defects
 Design changes that will eliminate the source of defects or errors
 Verify that the design will meet the requirements

Roles in Six Sigma

Why is Lean Six Sigma gaining the importance in today’s scenario?
Today’s environment is very dynamic. Lean or six sigma approach in this dynamic environment
cannot bring full potential to improvements if applied in isolation. Integration of Lean & Six
Sigma ensures exceptional improvements. In this management approach, traditionally the lean
methodology is used first to remove the waste in a process. Later, the Six Sigma tools are used to
improve process variations. However, these two methods go hand in hand in today’s time. The
ultimate objective is to improve processes by reducing variation and eliminating waste. It’s a
continuous improvement process, where Lean methods and Six Sigma approaches, both take
their turn during PDCA. The extent of approaches may differ depending upon process
complexities or improvement sought. The combination of these two methods helps to develop
streamlined processes with high quality & results. It improves bottom-line profits and helps
meeting business goals

Benefits of using Lean Six Sigma

The benefits are boundless, as Lean Six Sigma increases revenue and reduces costs, while
freeing up resources that can be utilized toward any endeavor your organization wishes to
For example:

 A new product or service

 Other improvement projects
 Expanding your sales force

Lean Six Sigma not only increases revenue and reduces costs, it positively affects people by
engaging them in improving the way they work. Since employees are the closest to the actual
work (production of a product or delivery of a service) of any organization, they become the best
resources to understand how to improve the efficiency and effectiveness of business processes.
By participating in successful Lean Six Sigma projects, employees are able to build the
confidence and develop the capability to become your business’ most important assets. Studies
show that when employees feel that they have a positive effect on the organization, they perform
better, are more accountable and live happier lives. And once your employees get comfortable
with Lean Six Sigma skills, they can continue to find and remove problems and waste in