Foundations of Lean Six Sigma

This unit introduces core Lean and Six Sigma concepts, process thinking, and customer-centered tools that form the foundation for improvement work. Students learn process mapping, variation and root-cause thinking, basic project definition techniques (including voice of the customer and brief project charters), and an overview of complementary approaches (Design for Six Sigma, Design Thinking, and Agile) to prepare for applied DMAIC work in subsequent units.

Learning Objectives

• Analyze core Lean and Six Sigma principles (waste reduction, variation control, and Theory of Constraints) and explain how they guide process improvement decisions in manufacturing and product development contexts
• Apply process-visualization and customer-focused techniques (e.g., SIPOC, flowcharts, Kano analysis, and VOC collection) to define and scope a concise Lean Six Sigma improvement project
• Demonstrate the ability to classify process steps as value-adding, non-value-adding, or necessary non-value-adding, and use basic variation and root-cause identification tools to prioritize improvement opportunities
• Evaluate deployment and team factors (stakeholder roles, standardization, prevention tools, DFSS, Design Thinking, and Agile considerations) and produce a brief project charter that gains initial stakeholder acceptance