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Lean Tools for Process Control in Six Sigma

In the final stages of a Six Sigma project, teams need to control the improved process in order to sustain the improvements. Process control involves applying tools to continuously monitor and maintain each improved process, and to prevent it from reverting to its previous state. Two tools from the Lean toolset specifically help here. Total Productive Maintenance (TPM) is a proactive equipment maintenance program that seeks to engage employees at all levels and functions in an organization to maximize the overall effectiveness of existing processes and equipment. The Visual Workplace is a Lean tool that uses visuals such as signs, labels, and color-coded markings to prevent workers from wasting time and effort searching for materials. This course explores how TPM can be used to control the improved process and maintain process gains. It also presents the elements of a visual factory and describes how the visual factory provides at-a-glance information about process status, targets, and performance. This course is aligned to the ASQ Body of Knowledge and is designed to assist Green Belt candidates toward their certification and to become productive members on their Six Sigma project teams.

Target Audience
Candidates seeking Six Sigma Green Belt certification; quality professionals, engineers, production managers, and frontline supervisors; and process owners and champions charged with the responsibility of improving quality and processes at the organizational or departmental level

Expected Duration (hours)

Lesson Objectives

Lean Tools for Process Control in Six Sigma

  • recognize features of Total Productive Maintenance (TPM)
  • identify characteristics of an organization that has implemented TPM's principle of shared responsibility
  • recognize the goals of Total Productive Maintenance (TPM)
  • recognize key concepts related to Total Productive Management (TPM)
  • classify examples of visual cues as visual controls, visual displays, or both
  • recognize examples of common jidoka devices
  • recognize examples of tools that keep employees in direct contact with the workplace
  • recognize examples of tools that clarify targets for improvement
  • determine which tools to use in a visual factory
  • recognize examples of ways Total Productive Maintenance is used in the service industry
  • recognize examples of a visual workplace
  • recognize how control tools are used in the service industry



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