Lean Six Sigma Green Belt

Certification Course
Lean Tools
 Learning Objectives

By the end of this lesson, you will be able to:

Identify Lean techniques that help in waste elimination

Explain the benefits of cycle time reduction

Differentiate between Kaizen and Kaizen Blitz

 Do You Know

Q Now that we have identified the causes that impact us the

most, we need to implement solutions or countermeasures.
What are the types of solutions that can be implemented?

A Lean tools can be implemented for solutions or

countermeasures.
Tools to Improve Processes
Lean Tools and Techniques

Kaizen

Poka Yoke

5S

JIT

Kanban

Jidoka

Takt Time

Heijunka
 Lean Tools and Techniques

All incremental changes routinely applied and sustained over a

Kaizen long period of time result in significant improvement.

Poka Yoke

5S

JIT

Kanban

Jidoka

Takt Time

Heijunka
 Lean Tools and Techniques

Kaizen

It is good to do it right the first time and even better to

Poka Yoke make it impossible to do it wrong the first time.

5S

JIT

Kanban

Jidoka

Takt Time

Heijunka
 Lean Tools and Techniques

Kaizen

Poka Yoke

The five steps to get an organized work area are Sort,

5S
Set in Order, Shine, Standardize, and Sustain.

JIT

Kanban

Jidoka

Takt Time

Heijunka
 Lean Tools and Techniques

Kaizen

Poka Yoke

5S

Producing the required units, in the required quantity,

JIT
at the right time, and with the required quality.

Kanban

Jidoka

Takt Time

Heijunka
 Lean Tools and Techniques

Kaizen

Poka Yoke

5S

JIT

Utilizing visual display cards to signal the movement of

Kanban material between the steps of a product process.

Jidoka

Takt Time

Heijunka
 Lean Tools and Techniques

Kaizen

Poka Yoke

5S

JIT

Kanban

Implementing supervisory function in production line and

Jidoka stopping the process as soon as a defect is encountered.

Takt Time

Heijunka
 Lean Tools and Techniques

Kaizen

Poka Yoke

5S

JIT

Kanban

Jidoka

The maximum time in which the customers’

Takt Time demands need to be met.

Heijunka
 Lean Tools and Techniques

Kaizen

Poka Yoke

5S

JIT

Kanban

Jidoka

Takt Time

Reducing waste that occurs due to

Heijunka
fluctuation in customer demand.
Cycle Time Reduction
 Cycle Time Reduction

Cycle time reduction is the reduction in the time taken to complete a process.

Increases productivity and throughput

Releases resources early

Reduces internal and external waste

Simplifies the operational process

Decreases product damage

 Cycle Time Reduction

Old Process Improved Process

In In

Process 1
Process 1 Process 2
Operator 1
Lean Techniques
Process 4 Operator 1 Operator 2
Operator 3
Process 5 Operator 4
Process 5 Process 4 Process 3
Operator 5

out Process 3 Process 2

Operator 3 Operator 2 out
 Kaizen and Kaizen Blitz

Kaizen is a continuous improvement Kaizen Blitz is known as Kaizen event or Kaizen workshop.

method to improve the functions of an If the event is tightly defined and the scope is evident for
organization. implementation, processes can be easily changed and
improved.

The improvements could be in: Teams improve processes through structured workshops.

• Process
• Productivity
• Quality
• Technology
• Safety
 Kaizen and Kaizen Blitz

Is a method Is a workshop or an event

Brings in incremental change Brings rapid solutions when required

Plans, executes the event, decides a solution, and

Standardizes, measures, and compares the process follows it through

Is lead by the management and the team Is lead by the management

Relatively delays the process of decision making Accelerates the process of decision making

Is a continuous improvement process Is a part of improving the process

 Kaizen and Kaizen Blitz

Kaizen Kaizen Blitz

In Toyota, the production In Wood Infinity Private

cycle is resumed after Limited, scraps are eliminated,
the problem is identified work areas are reorganized,
and solved. and inventory is reduced.
 Key Takeaways

The 8 Lean techniques are Kaizen, Poka Yoke, 5S, JIT, Kanban,
Jidoka, Takt time, and Heijunka.

Cycle time reduction refers to the reduction in the time taken to

complete a process.

Kaizen is a continuous improvement method to improve the

functions of an organization.

Kaizen Blitz is known as Kaizen event or Kaizen workshop.

If the event is tightly defined and the scope is evident for
implementation, processes can be easily changed and
improved.
Knowledge Check
Knowledge
Check Which Lean technique focuses on reducing waste caused by fluctuating customer
1 demand?

A. Jidoka

B. Heinjunka

C. 5S

D. Kanban
 Knowledge
Check Which Lean technique focuses on reducing waste caused by fluctuating customer
1 demand?

A. Jidoka

B. Heinjunka

C. 5S

D. Kanban

The correct answer is B

Heinjunka is a Lean technique that focuses on reducing waste caused by fluctuating customer demand.
Knowledge
Check
Which of the following is true about Kaizen and Kaizen Blitz?
2

A. Both focus on continuous improvement

B. Both are led by management teams

C. Both are events or workshops

D. Both bring incremental change

 Knowledge
Check
Which of the following is true about Kaizen and Kaizen Blitz?
2

A. Both focus on continuous improvement

B. Both are led by management teams

C. Both are events or workshops

D. Both bring incremental change

The correct answer is A

Kaizen and Kaizen events are different in many aspects but both focus on improving performance
Knowledge
Check
Which of the following Lean tools is focused on preventing defects from occurring?
3

A. JIT

B. Takt Time

C. 5S

D. Poka Yoke
 Knowledge
Check
Which of the following Lean tools is focused on preventing defects from occurring?
3

A. JIT

B. Takt Time

C. 5S

D. Poka Yoke

The correct answer is D

Poka Yoke is a Lean technique that focuses on preventing errors from occurring in a process.