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Lean Sigma--A Practitioner's Guide, 2nd Edition

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Lean Sigma--A Practitioner's Guide, 2nd Edition


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  • Written in an easily usable form, it provides students with proven roadmaps for project success
  • Shows how to make Lean Sigma suit the organization's needs, rather than having the organization have to re-invent itself
  • Lean Sigma focuses on removing unnecessary tasks or steps
  • Based on the author's years of experience training and consulting on Six Sigma


  • Copyright 2016
  • Dimensions: 7" x 9-1/4"
  • Pages: 592
  • Edition: 2nd
  • Book
  • ISBN-10: 0-13-399103-2
  • ISBN-13: 978-0-13-399103-1

The Practical Guide to Lean Sigma Problem-Solving— Expanded & Updated!

Lean Sigma delivers results—if you use the right tools and techniques. In this thoroughly updated edition, Ian Wedgwood details his proven best-practices from more than sixty successful Six Sigma and Lean deployments in multiple industries, helping you identify and apply the solutions that will work best in your projects.

This expanded edition of Lean Sigma: A Practitioner’s Guide offers detailed guidance on process improvement, standardization, accelerated improvement, and more. Wedgwood helps you identify potential Lean Sigma projects, even in processes without obvious targets. He illuminates fast, effective routes to solving specific business problems, and explains why these solutions work.

Next, he presents detailed “tools roadmaps”: step-by-step instructions showing exactly how and when to use each of these tools:

• 5 Whys

• 5S

• Affinity


• Box plot

• Capability

• C&E matrix

• Chi-Square

• Concept ideation, design, selection

• Control charts

• Control plan summary

• Core process map

• Critical path analysis

• Customer interviewing

• Customer requirements tree

• Customer surveys

• D-Study

• Demand profiling

• Demand segmentation


• Fishbone diagram

• Handoff map

• KPOVs & data

• Load chart

• MSAs

• Multi-Cycle analysis

• Multi-Vari studies

• Murphy’s analysis

• Normality test


• Pareto chart

• Process performance mgmt.

• Poka Yoke

• Process board

• Process FMEA

• Process scorecard /dashboard

• Process variables (I/O


Author's Site

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Sample Content

Online Sample Chapter


Table of Contents

Preface xiii

Acknowledgments xvii

About the Author xix

Chapter 1: Introduction 1

Overview 1

Intended Audience 2

Prerequisites 2

Basics 3

How to Use This Book 9

And Finally . . . 12

Part I: Project Roadmaps to Solve Business Problems 13

Chapter 2: Process Improvement Projects (DMAIC) 15

Overview 15

Define 15

Measure and Analyze 24

Improve 26

Control 33

Chapter 3: Standardization Projects (DMASC) 39

Overview 39

Define 42

Measure 45

Analyze 46

Standardize 47

Control 52

Chapter 4: Accelerated Improvement Projects (Kaizen) 57

Overview 57

Pre-Event 59

Event 63

Post-Event 71

Chapter 5: Discovery—Identifying Projects 75

Overview 75

Tool Approach 77

Part II: Routes to Solution 81

Chapter 6: Global Process Problems 83

A: On-Time Delivery Issues 83

B: Capacity of Process Is Too Low 87

C: RTY, Defects, Accuracy, Quality, Scrap, and Rework Issues 89

D: %Uptime Is Too Low 93

E: Pace of Process Is Too Slow 96

F: Process Has Enough Capacity but Fails Intermittently 99

G: Process Has Enough Capacity, but Process Lead Time Is Too Long 102

H: Individual Steps Meet Takt, Global Process Does Not 105

I: Demand from the Customer Is Too Variable 108

J: Too Many Entity Types (Products) 112

K: High Schedule Variation 115

L: Measurement System Broken 121

M: Performance Characteristic Not Good Enough 124

N: Planned Maintenance Takes Too Long 125

O: Setup/Changeover Takes Too Long 126

P: Too Much Unplanned Maintenance 129

Q: Process Can’t Make Product at All 134

R: Resource Usage Is Too High (Headcount Reduction) 136

S: Inventory Is Too High 139

T: Waste/Process Loss Is Too High 144

U: High Forecast Variation 147

V: Not Enough Sales 152

W: Backlog of Orders Is Too High 154

X: Payments Made to Suppliers Not Optimized 155

Y: Accounts Receivable Are Too High 158

Chapter 7: Individual Step Process Problems 163

1: A Single Process Step Does Not Meet Takt 163

2: The Pace for a Single Process Step Is Too Slow 166

3: Too Much Variation in the Cycle Time of a Single Step 168

Part III: Roadmaps to Guide in the Practical Application of Each Lean Sigma Tool 171

Chapter 8: Tools 173

01: 5 Whys 173

02: 5S 176

03: Affinity 184

04: ANOVA 187

05: Box Plot 196

06: Capability—Attribute 199

07: Capability—Continuous 201

08: Cause and Effect (C&E) Matrix 209

09: Chi-Square 213

10: Concept Ideation, Design, and Selection 219

11: Control Charts 226

12: Control Plan Summary 234

13: Core Process Map 242

14: Critical Path Analysis 246

15: Customer Interviewing 249

16: Customer Requirements Tree 258

17: Customer Surveys 261

18: D-Study 267

19: Demand Profiling 272

20: Demand Segmentation 277

21: DOE—Introduction 283

22: DOE—Screening 294

23: DOE—Characterizing 303

24: DOE—Optimizing 318

25: Fishbone Diagram 330

26: Handoff Map 334

27: KPOVs and Data 338

28: Load Chart 349

29: MSA—Validity 353

30: MSA—Attribute 357

31: MSA—Continuous 365

32: MSA—Process Variation Study (Nested ANOVA) 375

33: Multi-Cycle Analysis 380

34: Multi-Vari Studies 386

35: Murphy’s Analysis 391

36: Normality Test 394

37: Overall Equipment Effectiveness (OEE) 397

38: Pareto Chart 404

39: Process Performance Management 407

40: Poka Yoke (Mistake-Proofing) 410

41: Process Board 414

42: Process FMEA 418

43: Process Scorecard/Dashboard 423

44: Process Variables (Input/Output) Map 429

45: Project Charter 432

46: Pull Systems and Kanban 441

47: Rapid Changeover (SMED) 454

48: Regression 461

49: SIPOC 471

50: Spaghetti (Physical Process) Map 475

51: Standard Work Instructions 479

52: Statistical Process Control (SPC) 484

53: Swimlane Map 488

54: Test of Equal Variance 494

55: Time—Global Process Cycle Time 497

56: Time—Individual Step Cycle Time 500

57: Time—Process Lead Time 503

58: Time—Replenishment Time 506

59: Time—Takt Time 509

60: Total Productive Maintenance 514

61: t-Test—1-Sample 516

62: t-Test—2-Sample 522

63: t-Test—Paired 528

64: Value Stream Map 529

Index 541


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