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Even though Lean and Six Sigma are more than a set of tools. Here are some commonly used tools / methodologies in Lean:

  • Waste Identification
  • Standard Operating Procedures (SOP)
  • Continuous Improvement (Kaizen)
  • Value Stream Mapping (VSM)
  • Metrics (Cycle Time, TAKT Time, Process Cycle Efficiency)
  • Planning (A3, Hoshin-Kanri)
  • Mistake Proofing (Poka-Yoke)
  • Total Productive Maintenance (TPM)
  • Single Minute Exchange of Dies (SMED)
  • Load Balancing (Heijunka)
  • Plan - Do - Check - Act Cycle (PDCA)
  • Visual Controls
  • Pull Systems (Kanban, Supermarket, FIFO)
  • Flow Concepts
  • Line Balancing
  • Just in Time Concepts
  • Autonomation
  • Workforce Engagement
  • Workplace Organization (5S)
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Lean is a simpler concept for people of any industry to follow and focusses on removing wastes.

A 2-day activity of mapping the as-is process, identifying nonvalue adds and getting the stakeholders sign off to eliminate them can give huge results. Some of such activities have brought down the TAT of products by 50-90%.

6S helps in creating workplace discipline and saves manual effort in locating tools and files.

Visual Controls do wonder!!!! Run an internal competition amongst teams indicate if they are Red, Amber or Green and see the transformation take place right under your eyes.


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