Editorial Review:
Combining lean manufacturing with Six Sigma quality assurance creates a one-two punch that can transform results in any manufacturing environment. Lean Six Sigma That Works is filled with detailed, practical processes that let readers leave the conference room, and get right to work. Clear and simple, it's an ideal guide for both seasoned professionals and those implementing their first lean sigma project. The book offers a step-by-step improvement strategy, plus an understanding of: * cost, cash flow, materials velocity, lead time, balance, waste, and non-value-added processes * value stream mapping and the DMAIC process for solving problems and improving quality profitability * how every form of waste impacts customer satisfaction and the bottom line * and much more. A strong and sensible combination of the "why" and the "how," Lean Six Sigma That Works offers a clear path to high quality, customer loyalty, and indisputable results.
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Customer Reviews
Average Customer Rating: 
A practical approach to eliminating waste while improving quality 2008-07-25
This is a practical program for getting lean by removing waste and reducing nonvalue add activities while simultaneously removing defects, errors, and thereby improving quality. I like the way the authors discuss the principles without wallowing in theoretical abstractions. This is about getting to it rather than trying to talk it to death.
The book is in two parts. The first part is called "The What" and provides an overview of Lean Six Sigma, why you need to view everything from the point of view of the customers, what waste is, what value added really is and why everything else is nonvalue added even if it is required (such as payroll). They also show you why you want a balanced flow manufacturing system rather than the traditional batch system. You are also given an introduction to concepts such as velocity, throughput, lead time, cost, and profit. Their note that cash flow can mask unprofitability for awhile is apt. As is their warning you that profitability with a negative cash flow is certain death.
Part 2 is "The How". The authors show you the basic tool set for Lean Six Sigma, how to get a good baseline, how to do a lean engineering analysis, what to do about setups, what the 5S method is (it is about having a clean and well organized workplace) and the sixth S of Safety. I enjoyed the discussion of Total Productive Maintenance being everyone's job rather than just the maintenance staff and the costs of cheating proper maintenance. You are then taken through four practical exercises that remove indirect expenses, increase assembly line throughput, reducing warranty costs, and eliminating rework. The last chapter is the psychology of Lean Six Sigma, which is a passionate and tenacious commitment to relentless improvement.
Good stuff.
Reviewed by Craig Matteson, Ann Arbor, MI
Clarifying the chaos 2007-10-11
Carreira and Trudell do a good job of explaining the one-two punch of Lean and Six Sigma. Waste and process variability adds billions of dollars to the goods and services we use every day. Ever get the feeling it takes two or three tries to accomplish any task or conduct any business ? Lean Six Sigma helps to 'de-hassle' any process and ensure a no-surprise outcome. Read the book, Carriera and Trudell show you the way.
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