Lean Six Sigma Yellow Belt

INTRODUCTION 7
HOW TO USE THIS BOOK 8
PREFACE 9

1 WORLD CLASS PERFORMANCE 11
1.1 CONTINUOUS IMPROVEMENT 12
1.1.1 Continuous Improvement history 12
1.1.2 Continuous Improvement values and principles 17
1.1.3 Continuous Improvement Maturity Model (CIMM) 27
1.1.4 Continuous Improvement roles and responsibilities 30
1.2 CUSTOMER VALUE 32
1.2.1 Voice of the Customer (VOC) 32
1.2.2 Critical to Quality (CTQ) 34

2 POLICY DEVELOPMENT AND DEPLOYMENT 37
2.1 POLICY DEVELOPMENT 38
2.1.1 Vision & True North 38
2.1.2 Transformation roadmap 41
2.1.3 Performance and financial metrics 42
2.2 POLICY DEPLOYMENT 45
2.2.1 Management of change 46

3 PROJECT MANAGEMENT 49
3.1 MANAGING A PROJECT 50
3.1.1 Project selection 50
3.1.2 Project charter 52
3.2 PROCESS IMPROVEMENT ROADMAPS 55
3.2.1 Kaizen roadmap (PDCA) 55
3.2.2 Lean Six Sigma roadmap (DMAIC) 58
3.2.3 Scrum 61

4 CIMM LEVEL I – CREATING A SOLID FOUNDATION (STRUCTURED) 65
4.1 PROFESSIONAL WORK ENVIRONMENT 66
4.1.1 Organized Work Environment (5S) 66
4.2 STANDARDIZED WORK 72
4.2.1 Standard Operating Procedure 72
4.3 QUALITY MANAGEMENT 75
4.3.1 Quality Management System 75

5 CIMM LEVEL II – CREATING A CONTINUOUS IMPROVEMENT ENVIRONMENT (MANAGED) 79
5.1 VISUAL MANAGEMENT 80
5.1.1 Visual work environment 80
5.2 PERFORMANCE MANAGEMENT 82
5.2.1 Daily stand-up meetings 82
5.2.2 Kaizen events and problem solving 86
5.3 BASIC QUALITY TOOLS 89
5.3.1 Brainstorm techniques 89
5.3.2 Visualization of data 94

6 CIMM LEVEL III – CREATING STABLE AND EFFICIENT PROCESSES (PREDICTABLE) 103
DEFINE 105
6.1 PROCESS MAPPING 105
6.1.1 High level process description and SIPOC 105
6.1.2 Process Flow diagram 110
MEASURE 112
6.2 PERFORMANCE MANAGEMENT 112
6.2.1 Performance metrics (Time) 112
6.2.2 Performance metrics (Quality) 116
6.3 BASIC STATISTICS 118
6.3.1 Data types and Measurement scales 118