Lean Six Sigma combines the principles of Lean and Six Sigma, aiming to enhance organizational performance by improving efficiency and quality. Understanding its terminology is crucial for successful implementation. This detailed glossary explains key Lean Six Sigma terms clearly and concisely.
Lean Six Sigma Basic Glossary
1. 5S
A workplace organization method consisting of five phases:
- Sort (Seiri): Removing unnecessary items.
- Set in Order (Seiton): Arranging items for optimal efficiency.
- Shine (Seiso): Keeping the workplace clean.
- Standardize (Seiketsu): Establishing consistent practices.
- Sustain (Shitsuke): Maintaining improvements through discipline.
2. 7 Wastes (Muda)
Lean identifies seven main types of waste:
- Transportation
- Inventory
- Motion
- Waiting
- Overproduction
- Over-processing
- Defects
3. 8th Waste
Often added as “Unused Talent,” referring to not fully utilizing employees’ potential and creativity.
4. DMAIC
A structured improvement methodology central to Six Sigma:
- Define: Establish project scope and objectives.
- Measure: Collect data and quantify issues.
- Analyze: Identify root causes of problems.
- Improve: Implement solutions.
- Control: Maintain improvements through sustained practices.
5. DMADV
Used to create new processes or products:
- Define: Establish goals.
- Measure: Identify customer needs and specifications.
- Analyze: Develop design alternatives.
- Design: Optimize and plan the detailed design.
- Verify: Validate the design through testing.
6. Kaizen
A Japanese concept meaning continuous, incremental improvement involving all employees.
7. Kanban
A visual management tool used to control production flow and manage inventory levels, based on actual demand.
8. Just-In-Time (JIT)
A production methodology aimed at producing exactly what is needed, when needed, and in the right quantity.
9. Value Stream Mapping (VSM)
A visual tool to analyze and optimize processes by mapping the flow of materials and information.
10. Pull System
Production driven by actual customer demand, reducing inventory and waste.
11. Root Cause Analysis (RCA)
Techniques to identify fundamental reasons for problems or defects, often using tools such as Cause-and-Effect Diagrams and 5 Whys.
12. Control Chart
A statistical tool used to monitor process variation over time, distinguishing between common and special causes of variation.
13. FMEA (Failure Mode and Effects Analysis)
A systematic approach for identifying potential failures in processes, prioritizing risks, and planning mitigation strategies.
14. Gemba
A Japanese term meaning “the real place,” emphasizing observing and understanding work processes directly where they occur.
15. Heijunka
The practice of leveling production to match demand, reducing fluctuations, and creating a smoother workflow.
16. Poka-Yoke
Error-proofing techniques designed to prevent or detect mistakes automatically.
17. SIPOC
A high-level process mapping tool representing Suppliers, Inputs, Process, Outputs, and Customers, clarifying scope and relationships.
18. Voice of the Customer (VOC)
Collecting and analyzing customer feedback to understand needs, expectations, and perceptions.
19. Cycle Time
The total time from beginning to end to complete one cycle of a process or production task.
20. Lead Time
The duration from the initiation of a process until its completion and delivery to the customer.
21. Takt Time
The rate at which a product must be produced to meet customer demand, calculated as available production time divided by customer demand.
22. Standard Work
Documentation of the best method currently known to perform a task consistently and efficiently.
23. Sigma Level
A metric indicating how well a process performs, measured in defects per million opportunities (DPMO).
24. Critical to Quality (CTQ)
Key measurable characteristics of a product or service crucial to customer satisfaction.
25. Benchmarking
The practice of comparing business processes and performance metrics against industry bests and best practices from other companies.
Conclusion
Understanding these fundamental Lean Six Sigma terms provides a solid foundation for effectively employing this powerful methodology. Organizations familiar with these concepts can better identify improvement opportunities, implement meaningful changes, and achieve sustainable operational excellence.