Lean Six Sigma Philosophy Introduction Quiz

The Toyota Way: A New Way of Thinking

• The Toyota Way consists of 14 principles, organized into four sections: Long-Term Philosophy, The Right Process, Add Value to the Organization by Developing Your People, and Continuous Improvement.

Long-Term Philosophy

• Base management decisions on a long-term philosophy, even at the expense of short-term financial goals.
• People need purpose to find motivation and establish goals.
• Establish a long-term vision and strategy, like Toyota's 500-year strategic plan.

The Right Process Will Produce the Right Results

• Use continuous flow to produce work to an even production level.
• Level out workload to minimize waste, avoid overburdening people or equipment, and maintain even production levels.
• Standardize tasks and processes to empower employees and facilitate continuous improvement.
• Use visual control systems to ensure no problems are hidden.
• Use only reliable technology that serves people and processes.

The 5S Program

• Sort: Sort out unneeded items.
• Straighten: Have a place for everything.
• Shine: Keep the area clean.
• Standardize: Create rules and standard operating procedures.
• Sustain: Maintain the system and continue to improve it.

Add Value to the Organization by Developing Your People

• Grow leaders who understand the work, live the philosophy, and teach others.
• Empower employees to aid in growth and improvement through continuous improvement (kaizen).
• Leadership must be ingrained and become a way of thinking.
• Educate and train employees to maintain a learning organization.

Principle 8: Reliable Technology

• Use reliable, thoroughly tested technology that serves people and processes.
• Base technology on "prototyping" or creation of multiple working sets of information subject to improvement.

Principle 9: Leadership

• Grow leaders who thoroughly understand the work, live the philosophy, and teach it to others.

Principle 10: Teamwork

• Develop exceptional people and teams who follow the company's philosophy.
• Teams should consist of 4-5 people and numerous management tiers.
• Success is based on the team, not the individual.

Principle 11: Respect Suppliers

• Respect extended network of partners and suppliers by challenging them and helping them improve.
• Treat suppliers like employees, challenging them to do better and helping them achieve it.

Continuous Improvement

• Continuously solving root problems drives organizational learning.
• Go and see the problem for yourself to thoroughly understand the situation (Genchi Genbutsu).
• Decision making should be by consensus.
• Reflection is essential for continuous improvement.

Lean Manufacturing

• Lean manufacturing aims to make a product in the most efficient and effective manner, while continuously improving.
• Decrease cycle time, eliminate sources of waste, and increase throughput.

History of Lean

• Lean manufacturing started with Henry Ford's assembly line in the early 1900s.
• Taichi Ohno and Kiichiro Toyoda created the Toyota Production System after WWII.
• Lean manufacturing is about making a product in the most efficient and effective manner, while continuously improving.