Lean Concepts

5S

Eliminating Waste

Lean Six Sigma Integration

The Seven Muda

Over-Processing

Key Waste Types

Waiting (Muda of Waiting)

Lean concepts are often combined with Six Sigma for process improvement

Defects and Waste

Six Sigma defects result from process failures, causing financial losses and damage to reputation

Waste includes unnecessary time, labor, or material in processes

  • Seven common types of waste (muda) include overproduction, correction, inventory, motion, conveyance, over-processing, and waiting

Inventory: Accumulation of materials before a process step; reduce batch sizes

Motion: Unnecessary employee movements during a process; streamline processes

Correction: Reworking defective work; root causes should be addressed

Conveyance: Unnecessary movement of outputs or resources; analyze and eliminate

Overproduction: Producing too much too soon; planning is essential

Lean principles focus on planning, process changes, layout adjustments, and addressing root causes to eliminate waste in various forms

Investing more resources than valued by the customer

Idle time in a process for machinery or people

Sort, Straighten, Shine, Standardize, Sustain

Just-in-Time Manufacturing(JIT)

Produce output just in time, minimizing waste

Supplying required parts in sync with demand