Lean Six Sigma for Small and Medium Sized Enterprises A Practical Guide

It is no secret that Lean Six Sigma (LSS) is not as popular with small and medium-sized enterprises (SMEs) as it is with larger ones. However, many SMEs are suppliers to larger entities who are pushing for superior quality and world-class process efficiencies from suppliers.Lean Six Sigma for Small and Medium Sized Enterprises: A Practical Guide provides a roadmap for the successful implementation and deployment of LSS in SMEs. It includesfive real-world case studies that demonstrate how LSS tools have been successfully integrated into LSS methodology. Simplifying the terminology and methodology of LSS, this book makes the implementation process accessible. Supplies a general introduction to continuous improvementinitiatives in SMEs Identifies the key phases in the introduction and development of LSS initiatives within an SME Details the most powerful LSS tools and techniques that can be used in an SME environment Provides tips on how to make the project selection process more successful This book covers the fundamental challenges and common pitfalls that can be avoided with successful introduction and deployment of LSS in the context of SMEs. Systematically guiding you through the application of the Six Sigma methodology for problem solving, the book devotes separate chapters to the most appropriate tools and techniques that can be useful in each stage of the methodology.Keeping the required math and statistics to a minimum, this practical guide will help you to deploy LSS as your prime methodology for achieving and sustaining world-class efficiency and effectiveness of critical business processes.

Introduction to Small and Medium-Sized Enterprises (SMEs) IntroductionDefinition of SMEsSMEs’ Contribution to World EconomyCharacteristics of SMEsSMEs versus Larger FirmsSummaryReferencesContinuous Improvement Initiatives in SMEsWhat is Continuous Improvement?Continuous Improvement Practices in Small and Medium-Sized Enterprises (SMEs)Critical Success Factors in the Implementation of CI Practices in SMEsLeadership for CISustainability of CI InitiativesSummaryReferencesLean Six SigmaWhat is Lean Production System?Key Principles of Lean Production SystemBenefits of Lean Production SystemWhat is Six Sigma?Some Common Myths of Six SigmaAn Overview of Six Sigma MethodologyBenefits of Six SigmaSome Pros and Cons of Lean and Six SigmaWhy Lean Six Sigma?Benefits of Lean Six SigmaChallenges in the Implementation of Lean Six SigmaSummaryReferencesLean Six Sigma Road Map for SMEsReadiness Factors for the Successful Introduction of LSSLean Six Sigma Implementation InfrastructureA Road Map for Implementing Lean Six SigmaManagerial ImplicationsSummaryReferencesLean and Six Sigma MetricsIntroductionIntroduction to Common Metrics of LeanIntroduction to Common Metrics of Six SigmaLean Six Sigma MetricsOverall Equipment EffectivenessSummaryReferencesSix Sigma MethodologyIntroductionDefine PhaseMeasure PhaseAnalyze PhaseImprove PhaseControl PhaseSummaryReferencesBasic and Advanced Tools of Lean and Six Sigma for SMEsSuppliers, Inputs, Process, Outputs and CustomerValue Stream Mapping5S PracticeSingle Minute Exchange of DiesVisual ManagementStandard Operating ProceduresCause and Effect AnalysisPareto AnalysisHistogramScatter Diagram and Correlation AnalysisControl ChartsRun ChartsFailure Modes and Effects AnalysisVoice of the Customer AnalysisCTQs and a CTQ TreeProject CharterHypothesis TestsRegression AnalysisKanban SystemPoka-Yoke (mistake proofing)Root Cause Analysis or 5 Whys AnalysisDesign of ExperimentsProcess MappingMeasurement System AnalysisSolution Selection MatrixSummaryReferencesLSS Project SelectionWhat is an LSS project?Project Selection and PrioritizationManagement of Project ReviewsSome Tips for Making Your LSS Projects SuccessfulSummaryReferencesIndustrial Case Studies of Lean Six SigmaCase Study 1: Application of Six Sigma Methodology in a Small-Scale Foundry IndustryCase Study 2: Application of Six Sigma Methodology in Road Construction for Wind Turbine InstallationCase Study 3: Application of Six Sigma Methodology to Reduce the Rejection and Rework in an Automobile Supplier CompanyCase Study 4: Application of Value Stream Mapping in a Camshaft Manufacturing OrganizationCase Study 5: An Application of Lean Six Sigma to a Die Casting ProcessReferencesIndex

Jiju Antony is recognized worldwide as a leader in Six Sigma methodology for achieving and sustaining process excellence. He founded the Centre for Research in Six Sigma and Process Excellence (CRISSPE) in 2004, establishing the first research centre in Europe in the field of Six Sigma. Professor Antony has successfully completed a BE in mechanical engineering from the University of Kerala (South India), an MSc in industrial engineering from the National University of Ireland, Ireland, and a PhD in quality engineering from the University of Portsmouth, UK.S. Vinodh is an assistant professor in the Production Engineering Department of the National Institute of Technology, Tiruchirappalli. Dr. Vinodh completed his bachelor’s degree in mechanical engineering at Bharathiar University, Coimbatore, India; and master’s degree in production engineering and PhD in mechanical engineering at Anna University, Chennai, India.E.V. Gijo has worked as a faculty member in the Statistical Quality Control and Operations Research Division of the Indian Statistical Institute, Bangalore, India for the last 17 years. Dr. Gijo has successfully completed an MSc in statistics at M.G. University (Kerala), an M. Tech. in quality, reliability and operations research at the Indian Statistical Institute (Kolkata) and a PhD in statistics at M.G. University (Kerala).