ESD.60 | Summer 2004 | Graduate

Lean/Six Sigma Processes

Lecture Notes

In this course, some subtopics are covered by the instructor and some subtopics are covered by students. The projects listed below are presented courtesy of and used with the permission of the students named.

Part I: Foundations


Welcome and Overview

Lean Thinking

Course Syllabus and Expectations

Class Experience with Lean/Six Sigma

Historical Perspective on Lean/Six Sigma

Lean Thinking (PDF)

Mass and Lean in Historical Context

Exercises (Seven Wastes, 5S’s, Work Cell Redesign)

Value Stream Maps and Knowledge-Driven Continuous Improvement (PDCA)

Infrastructure, Stability, Flow and Pull

Prof. Joel Cutcher-Gershenfeld
2 Six Sigma Principles

Systems Change Principles

Six Sigma Principles (PDF)

Variance and Variance Reduction

DMIAC Process - y=f(x)

Six Sigma Measurement Tools

Systems Change Principles (PDF)

Stakeholders and Systems

OD Roles

Strategy, Structure and Process

“Top-Down” and “Bottom-Up” Change

Socio-Technical Dynamics (PDF)

Prof. Joel Cutcher-Gershenfeld
3 “Pre-Stability” Considerations “Brownfield”/“Greenfield” Contrast (PDF)

Active and Passive Opposition to Lean/Six Sigma (PDF)

Inadequate or Missing “Social Infrastructure” - Forums, Capabilities, Relationships

Prof. Joel Cutcher-Gershenfeld
Part II: Stability
4 Team-Based, Knowledge-Driven Work Systems Team/Work Group Structure and Roles - Socio-Tech vs Lean Teams (PDF)

“Front-Line Leadership Capability and Motivation” by Craig Abler and Thomas Neal (PDF)

Knowledge-Driven Work (PDF)

Prof. Joel Cutcher-Gershenfeld

Craig Abler and Thomas Neal

5 Manufacturing Stakeholder Alignment Support Function Alignment (PDF)

“Supply Chain Alignment” by Kevin Lennox and Dave Penake (PDF)

Union-Management Partnership (PDF - 1.7MB)

Prof. Joel Cutcher-Gershenfeld

Kevin Lennox and Dave Penake

6 In-Station Process Control and Standardized Work “Standardized Work” by Jessica Dolak and Ben Lathrop (PDF)

Statistical Process Control and “Control Points”

Andon Response Systems

“PDCA and Control Point Improvement Processes” by Jeremy Weinstein and Steve Vasovski (PDF)

Jessica Dolak and Ben Lathrop

Jeremy Weinstein and Steve Vasovski

7 Total Productive Maintenance and Standardized Support 5S’s and Waste Walks

“Preventive Maintenance Principles” by Scott Couzens and Scott Hiroshige (PDF)

Lean Machine Tooling

Maintenance/Skilled Trades Work Groups

Scott Couzens and Scott Hiroshige
Part III: Flow
8 Value Streams

“Assembly Operations - Takt Time” by Colin Ducharme and Todd Ruddick (PDF)

“Machining Operations - Cycle Time” by Tamboura Gaskins and Sean Holly (PDF)

“Continuous Flow Operations” by Bret Awbrey and Jacob Silber (PDF)

Engineering Design Operations Service Operations - Cycle Time

“Sustainability and Lean/Six Sigma” by Todd Robinson and Kerry Person (PDF - 1.0MB)

Colin Ducharme and Todd Ruddick

Tamboura Gaskins and Sean Holly

Bret Awbrey and Jacob Silber

Neil Bar, Todd Robinson and Kerry Person

9 Material Flow Kanban/Supply Chain Sequencing

“Presentation of Parts and Parts Marketplace” by Min Shao and Jason Kary (PDF)

“Hejunka/Product Leveling” by Amy Reyner and Kweku Fleming (PDF)

Min Shao and Jason Kary

Amy Reyner and Kweku Fleming

10 Knowledge and Information Flow “Kaizen-Teian Improvement Systems” by Yue Cathy Chang and Johnson Wu (PDF)

“Hoshin Planning/Policy Deployment” by Ian MacDonald and Howard Shen (PDF - 1.7 MB)

Enterprise Resource Planning Tools

Design for Manufacture

“Performance Metric Feedback” by Krishnan Raghunathan and Linsey Rubenstein (PDF)

Yue Cathy Chang and Johnson Wu

Ian MacDonald and Howard Shen

Krishnan Raghunathan and Linsey Rubenstein

Part IV: Pull
11 Customer “Pull” Systems

Auto Industry

Forecast “Push,” Customer “Pull,” and Hybrid Models by Bruce Pan and Nicholas Svensson (PDF)

The Three-Day Car

Bruce Pan and Nicholas Svensson
12 Aerospace Industry

Customer Support Operations

_Low Volume and High Complexity in Defense Aerospace
Fujitsu “Sense and Respond” Customer Support System
Prof. Joel Cutcher-Gershenfeld
Part V: Enterprise
13 Transitions from “Pre-Stability” to Stability to Flow to Pull (#13), and Lean Enterprise Alignment Principles (#14) Within-Function and Cross-Functional Challenges in the Transitions from “Pre-Stability” to Stability to Flow to Pull

Lean Enterprise Alignment (PDF)

Enterprise Structure and Alignment

Value Identification, Value Proposition and Value Delivery in the Enterprise Context

Concluding Course Overview

Prof. Joel Cutcher-Gershenfeld
14 Ready, Set, Go LFM Alumni Panel  
15 Lean Simulation A Simulation Exercise Designed to Illustrate Lean Principles in Manufacturing Operations (PDF 1 of 4 - 1.2 MB) (PDF 2 of 4 - 1.3 MB) (PDF 3 of 4 - 1.4 MB) (PDF 4 of 4 - 1.7 MB) Prof. Joel Cutcher-Gershenfeld

Course Info

As Taught In
Summer 2004
Learning Resource Types
Lecture Notes
Activity Assignments
Presentation Assignments
Written Assignments