Knowledge In Action: 10 Case Studies - Lean Six Sigma

The certification is done. The tools are familiar. But when the first real project arrives, with a live sponsor, operational constraints, and data that does not behave the way the textbook promised, knowing the tools is not enough. You need the judgement to choose between them.

This book provides that judgement through ten fully worked case studies across ten industries.

Each case study follows a single practitioner from the first sponsor briefing to the final control plan. Every analytical decision is shown. Every tool selection is explained, including which alternatives were considered and why they were rejected. Not just which tool was chosen. Why that one, and not the others.

What is inside:

Ten complete case studies in pharmaceutical manufacturing, retail banking, automotive assembly, telecoms, corporate HR, hospitality, software support, learning and development, ecommerce, and digital financial services. Nine case studies apply DMAIC. One introduces DMADV in full, with Kano Model, House of Quality, DFMEA, logistic regression, Weibull reliability analysis, and Monte Carlo simulation, showing what changes when the task is design rather than improvement.

Ninety worked exercises with complete model solutions, progressing from foundational to advanced numerical calculation.

Statistical and Lean tools applied across the series:

Two-factor ANOVA, Design of Experiments (fractional factorial, CCD, RSM, Taguchi), logistic regression, Weibull reliability analysis, Monte Carlo simulation, M/M/c queueing theory, acceptance sampling with OC curves, Attribute Agreement Analysis, Phase I and Phase II SPC with full Nelson rules, Kruskal-Wallis, Wilcoxon Signed-Rank, EWMA charts, OEE decomposition, SMED, Heijunka, TPM, and kanban.

What makes this different:

No existing case study book covers both DMAIC and DMADV with fully worked numerical examples. No other practitioner book names the rejected tools at every decision point and explains why they were set aside. No multi-industry LSS book provides ninety complete exercise solutions alongside the cases.

The problems in these ten case studies appear, on the surface, to have nothing in common. What they share is the moment when someone decided to ask what the data actually said, and discovered that the answer was different from what everyone in the organisation had believed. The improvement followed directly from that discovery.

For: Lean Six Sigma Green Belts, Black Belts, and Master Black Belts. Quality engineers, operations managers, and process improvement leads. Anyone who has completed LSS training and is now working on problems that do not arrive with a solution already attached.