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LSS Tools and

Techniques
A Training by Asadullah Qureshi (I&E)

Agenda
Basic Concepts
Refresher

DMAIC Review
Common LSS Tools &
Techniques

Live Exercise
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What is LSS?
A time-tested method and set of
tools to help us improve how we
produce our products and services.
LSS is also a mindset, where we ask
each day, how can we make our
services better for customers?

LSS Helps Us Understand

1. What adds value to our customers.
2. How work gets done.
3. How we can identify root causes of
problems.
4. What an ideal process looks like.
5. How we can improve performance.
6. Whether process changes were
successful.
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LSS Is About Simplifying

Our Work
Eliminate tasks that do not add
value.
Make things easy and intuitive for
customers and staff.
Automate repetitive tasks.
Leverage staff talent.

How Do We Define Valueadded?

Value-Added
vs.
Customer is willing
Consumes
Value-Added
to pay for it.
Actually
transforms a
product or service.
Done correctly the
first time.

Non

resources without
creating value for
the customer.
Requires extra
time, effort, or
resources.

Types of Waste

LSS is About Removing

Waste
Value
Added

Value
Added

Value
Added

Task time is typically 10% of total process time

(lead time).
Less than 30% of the tasks in a process add
value from the customers perspective.
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Improvement Strategies
Hand-offs and batching are common barriers to
process flow.

LSS Concepts and Tools

DMAIC Framework
5S
Poka-Yoke (Error
Proofing)
Visual Management
Kaizen / Work Out

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DMAIC Framework

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5S
A simple method for creating a clean, safe,
orderly, high performance work
environment.

1.
2.
3.
4.
5.
6.

Sort
Set In Order
Shine
Standardize
Sustain
Safety

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Before

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1S - Sort

When in
doubt, move it
out.

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2S - Set in Order
(Straighten)
A

place for
everything, and
everything in its
place.
A visual
management
strategy!
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3S - Shine
The best
cleaning is to
not need
cleaning.

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4S - Standardize
See and
recognize what
needs to be
done.

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5S - Sustain
Effective,
ongoing
application of
5S
The most
difficult step!
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After

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Poka Yoke Error

Proofing

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Visual Management
A communication device that tells, at a
glance, how work should be done.
Where items belong
How many items
Standard procedure
Work-in-process (WIP)
There is only one place to put each item.
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Visual Management
Examples

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Kaizen aka Work Out

A Kaizen Event is a
facilitated, smallscope improvement
activity that engages
the creativity of
employees to reduce
waste in a work
process. A Kaizen
Event typically lasts
3-5 days.
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LIVE EXERCISE

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Kaizen/Workout
Template

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The Process
The tea-boy has to serve tea to 5
people every morning in I&E Office.
He uses tea-bags and has a kettle for
boiling water.
Customer: 5 people in I&E Office
Voice of the Customer:
The tea tastes like tea flavoured water.
The tea gets to us at least 5 minutes late.
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Waste / Defects in the

Process
This is what he does wrong:
Uses very little milk.
Boils the water each time tea has to be
served.
Has no way of keeping the water hot
once it has been boiled.

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Exercise
TIME DURATION : 10 Minutes
Title
Define : Mention the problem in terms of time,
money, reliability or safety.
Measure & Analyze : Identify root cause and
quantify in terms of time, money, reliability or
safety.
Improvements : Mention how process has improved
and quantify in terms of time, money, reliability or
safety.
Control : Mention how you will sustain
improvements. (Hint: Develop SOPs)
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Thank You !

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