What is Lean and Six Sigma?

Instead of boring you with lots of words, we’ve compiled a set of videos that give you a good idea what you can do with process improvement. Feel free to use this page as an introductory education for those in your company, agency or organization.

Video #1 – One Piece Flow

The first video gets at the fundamental of lean, that work should be completed one job at a time. Once you start working on a customer request, you should not stop until it is complete and in their hands. Yet, most processes operate with numerous starts and stops due to delays or waiting on information or materials to proceed.

Did you figure out why the “single/one piece flow” approach work faster? It took me a while to figure it out the first time I saw this.

The extra handling (picking up and setting down the envelope, organizing the stack of items, and the movement to and from his workspace causes more delays than the setup between each step (fold, stuff, seal and stamp). This can be counterintuitive for many people. There are situations where operating a process in a batch mode is more efficient (when setups are long), however, the goal should be to reduce the setup time using SMED techniques, instead of continuing to batch.

Video #2 – Continuous Improvement (Kaizen)

Paul Akers, from FastCap, has figured out how to get ALL his employees engaged and constantly looking for ways to improve (kaizen), which is the most difficult thing to do. His passion and his leadership is contagious! He provides us with an example of how he coaches his employees to make dramatic reductions in task times.

Video #3 – One Piece Flow on Boeing 737 assembly (watch directly on YouTube)

Boeing setup their assembly line to operate in one piece flow, which forces them to work on one plane at a time. In addition, since the plane is constantly moving towards the customer at a set pace, it is easy to determine when something is wrong, so resources can be applied to help out, and get it back on track.

Video #4 – What is 5S (Workplace Organization)?

5S is one of the fundamental skills for process improvement, and this video shows how it is applied in a repro center on a college campus, while explaining all 5 steps of the process.

Video #5 – How NOT to do 5S! (Funny video)

To add some humor into the training, we found this video that makes me laugh every time! This is not the way to deploy 5S in a work area. Focus on current problems and how to resolve them, not going after changes that have no tangible benefits (at this time).

Video #6 – What is Six Sigma?

Six Sigma can be confusing at times, so we developed this video to explain how Six Sigma applies to golfing, to make it easier to understand sigma levels and variation.

If you found this training helpful, you might be ready for some of our training materials. Feel free to contact us if you have any questions, or would like a free, no-obligation consultation about your work or progress.