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

• ANOVA

• 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

• DOE

• Fishbone diagram

• Handoff map

• KPOVs & data

• Load chart

• MSAs

• Multi-Cycle analysis

• Multi-Vari studies

• Murphy’s analysis

• Normality test

• OEE

• Pareto chart

• Process performance mgmt.

• Poka Yoke

• Process board

• Process FMEA

• Process scorecard /dashboard

• Process variables (I/O) map

• Project charter

• Pull systems & Kanban

• Rapid changeover (SMED)

• Regression

• SIPOC

• Spaghetti map

• Standard work instructions

• SPC

• Swimlane map

• Test of equal variance

• Time

• Total productive maintenance

• T-tests

• Value stream map

With this guide, all Green, Black, or Master Black Belts will benefit from decades of Six Sigma and Lean consulting experience.

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Ian Wedgwood, Ph.D., President and CEO of Haelan Group, has more than two decades of experience guiding organizations through change. He has led and facilitated dozens of Lean Sigma deployments in industries as diverse as healthcare, electronics, engineered materials, chemicals, banking, and hospitality, and has trained and mentored numerous executives, Champions, and Belts.

Chapter 1: Introduction