Domain · Areas of Expertise

Lean Six Sigma

Green Belt certified. DMAIC-driven process improvement and waste elimination.

Beyond running DMAIC projects, I've researched why Lean Six Sigma adoption actually fails in small-scale industries - the barriers matter as much as the toolkit.

Hands-on Tools

Prioritize and pace the improvement

🔴 RPN risk ranking

FMEA Risk Priority Number

Failure Mode Analysis

RPN = Severity × Occurrence × Detection - ranks which failure modes to fix first.

Severity (1–10) Occurrence (1–10) Detection (1–10)

Enter values and calculate.

⏱ Demand-paced takt time

Takt Time Calculator

Flow & Pacing

The rate at which you must produce to match customer demand.

Available Time per Shift (min) Customer Demand per Shift (units)

Enter values and calculate.

✅ 5S maturity score

5S Audit Scorecard

Workplace Organization

Rate each S from 0 (absent) to 5 (fully embedded) for a quick workplace-organization health check.

Sort (0–5) Set in Order (0–5) Shine (0–5) Standardize (0–5) Sustain (0–5)

Enter ratings and score.

DMAIC Walkthrough

Engine Assembly Line Productivity

Same case study as the homepage tool, using the Maynard Operation Sequence Technique (MOST) to rebalance an engine assembly line.

Define

Engine assembly line was missing takt-time targets; cycle time imbalance across stations flagged as the core productivity constraint.

Measure

Station-wise cycle times captured and decomposed into elemental motions using MOST, establishing a baseline standard time per station.

Analyze

Line-balancing analysis identified bottleneck stations and non-value-adding motion sequences driving cycle-time variance.

Improve

Work elements re-sequenced and reallocated across stations using MOST-derived standard times to balance the line to takt time.

Control

Revised SOPs and station standard times documented for sustained line balance and future audits.

See the Work System Design domain for the line-balancing calculator behind step 3–4.

Case Study

Why Lean Six Sigma Adoption Stalls

Conference · 2022

Exploration of Barriers on Implementation of Lean Six Sigma in Small Scale Industries

ICAIEA International Conference, DoIE, CEG, Anna University

Identifies and structures the organizational, financial, and cultural barriers that stop small-scale industries from successfully adopting Lean Six Sigma - a reminder that tool fluency isn't the bottleneck; implementation context is.

Focus: LSS adoption barriers, SMEs