Lean Six Sigma
- Date: 2007-10-11 - Word Count: 600
Share This!
Lean Manufacturing and Six Sigma are wildly popular continuous improvement methodologies, utilized by thousands of corporations today.
Some companies decide to implement lean manufacturing, while others believe six sigma is the necessary initiative to improve their business. There is now a growing list of companies combining both methods under the initiative called Lean Six Sigma.
It is a fairly new approach, leaving many companies perplexed with the roadmap to implementation. It's not surprising, since implementing either lean manufacturing or six sigma alone is a daunting task.
Lean manufacturing consists of about 25 major concepts, such as 5s, SMED, Error Proofing, Quality at the Source, Line Balancing, OEE, Kanban, Value Stream Mapping, Cellular Manufacturing, and Standard Operations. Some companies spend a few years implementing these terrific principles into their organization.
Six sigma consists of a 5 phase methodology Define-Measure-Analyze-Improve-Control (DMAIC), utilizing hundreds of tools throughout the phases.
Combine both methods and all of these tools, and it's easy to understand why initiatives fail. Unless the organization has the expertise to handle the implementation and help focus the efforts, the program becomes a shotgun approach and is doomed to fail. Most organizations could not withstand the chaos and prolonged costs without substantial payback.
Both lean manufacturing and six sigma principles are proven to work. Many companies have increased business, reduced costs, increased throughput, and lowered cycle times using both approaches. It only makes sense to utilize every tool available to obtain the maximum improvement possible.
It is critical for companies to let the problem determine the tools that are needed, rather than determine the tool and try and force the use of it.
Some projects are obviously a lean manufacturing initiative. For example, if a machine has a 40 minute setup time and it is the bottleneck, then a SMED project is necessary. It may be part of a kaizen blitz or a simple SMED (single minute exchange of die).
There are clearly other projects which will be primarily a six sigma project. For example, a batch process plant using 12 different ingredients with various processes at different temperatures, speeds, and viscosities, would require a six sigma project to determine the best combination of machines, speeds, and viscosities to obtain maximum results. Some of the six sigma tools used would be statistical analysis, hypothesis testing, design of experiments, and analysis of variance (ANOVA).
There are many other types of projects where both lean manufacturing and six sigma tools would best solve the challenge. For example, suppose a batch processing problem involved the various ingredients, speeds, and temperatures. The best method might be a certain mix of machines, but the best one has a 5 person crew with a 2 hour setup time. It is time for the lean tools to reduce the cost per man hour utilizing OEE (Overall Equipment Effectiveness) tools as well as SMED, and possibly 5S.
A common use of lean tools in a six sigma project is during the Improve phase. The six sigma project Define, Measured, and Analyzed the problem, but a lean tool is necessary to solve it. Another six sigma tool will help Control it. If the company only used one of either six sigma or lean manufacturing tools, the problem may not get solved.
The beauty of six sigma is the methodical approach to opportunities. The advantage of lean manufacturing tools is the speed of implementation. When both tools are combined and used when necessary to solve business opportunities, the best result and greatest payback will be obtained.
Carl Wright is an industrial engineer, ASQ Six Sigma Black Belt, and Master Black Belt. Learn more about lean six sigma, lean manufacturing certification, and six sigma online training.
Some companies decide to implement lean manufacturing, while others believe six sigma is the necessary initiative to improve their business. There is now a growing list of companies combining both methods under the initiative called Lean Six Sigma.
It is a fairly new approach, leaving many companies perplexed with the roadmap to implementation. It's not surprising, since implementing either lean manufacturing or six sigma alone is a daunting task.
Lean manufacturing consists of about 25 major concepts, such as 5s, SMED, Error Proofing, Quality at the Source, Line Balancing, OEE, Kanban, Value Stream Mapping, Cellular Manufacturing, and Standard Operations. Some companies spend a few years implementing these terrific principles into their organization.
Six sigma consists of a 5 phase methodology Define-Measure-Analyze-Improve-Control (DMAIC), utilizing hundreds of tools throughout the phases.
Combine both methods and all of these tools, and it's easy to understand why initiatives fail. Unless the organization has the expertise to handle the implementation and help focus the efforts, the program becomes a shotgun approach and is doomed to fail. Most organizations could not withstand the chaos and prolonged costs without substantial payback.
Both lean manufacturing and six sigma principles are proven to work. Many companies have increased business, reduced costs, increased throughput, and lowered cycle times using both approaches. It only makes sense to utilize every tool available to obtain the maximum improvement possible.
It is critical for companies to let the problem determine the tools that are needed, rather than determine the tool and try and force the use of it.
Some projects are obviously a lean manufacturing initiative. For example, if a machine has a 40 minute setup time and it is the bottleneck, then a SMED project is necessary. It may be part of a kaizen blitz or a simple SMED (single minute exchange of die).
There are clearly other projects which will be primarily a six sigma project. For example, a batch process plant using 12 different ingredients with various processes at different temperatures, speeds, and viscosities, would require a six sigma project to determine the best combination of machines, speeds, and viscosities to obtain maximum results. Some of the six sigma tools used would be statistical analysis, hypothesis testing, design of experiments, and analysis of variance (ANOVA).
There are many other types of projects where both lean manufacturing and six sigma tools would best solve the challenge. For example, suppose a batch processing problem involved the various ingredients, speeds, and temperatures. The best method might be a certain mix of machines, but the best one has a 5 person crew with a 2 hour setup time. It is time for the lean tools to reduce the cost per man hour utilizing OEE (Overall Equipment Effectiveness) tools as well as SMED, and possibly 5S.
A common use of lean tools in a six sigma project is during the Improve phase. The six sigma project Define, Measured, and Analyzed the problem, but a lean tool is necessary to solve it. Another six sigma tool will help Control it. If the company only used one of either six sigma or lean manufacturing tools, the problem may not get solved.
The beauty of six sigma is the methodical approach to opportunities. The advantage of lean manufacturing tools is the speed of implementation. When both tools are combined and used when necessary to solve business opportunities, the best result and greatest payback will be obtained.
Carl Wright is an industrial engineer, ASQ Six Sigma Black Belt, and Master Black Belt. Learn more about lean six sigma, lean manufacturing certification, and six sigma online training.
Related Tags: lean manufacturing, six sigma, six sigma training, lean six sigma, lean manufacturing training
Your Article Search Directory : Find in Articles
Recent articles in this category:
- The No. 1 Rule For Projecting Confidence - Speak With Authority
One of the most important characteristics a person can project in a business setting - or any situat - After the Autumn Checkout European Debt Crisis and U.S. Brewing Rebound
In the commotion caused by the Fed on interest rates come to an end, the "disastrous" for the euro a - Advantages Of Arcade Game Rentals
There are many different advantages to arcade game rentals. Most people need something to release th - A General Primer on Truck Cargo Nets
In modern highways it is quite rare to see truck cargo nets in action, this is because they are usua - The United States Will Burst More Severe Financial Crisis
Not long ago, suddenly announced that the central bank to raise interest rates, the interest rate hi - Niche Marketing Profits - 3 Easy Steps to Finding a Profitable Niche Market Income in 10 Minutes
Like most beginners I was having a very difficult time trying to find a niche market to earn extra m - The Importance of Hospitality Management Consulting Firms Toronto
Businesses and the managers that help guide any business are in a constant state of improvement and - New Keynesian Theory Label
2010 winner of the Nobel Prize in Economics three theories have been labeled as "New Keynesian" labe - Federal Reserve Pouring Money QE2 Unpredictable Fortune
U.S. economist Milton Friedman proposed a "throw the cash from a helicopter" view, while the practic - Fiscal Consolidation Should no Longer Delay
British Chancellor of the Exchequer George Osborne today announced fiscal consolidation policy, shoc
Most viewed articles in this category:
- Common Financial Problems to Avoid
One must first change their habits and not procrastinate. American Consultants Inc at offers key fi - How a Bad Hire Can Hurt Your Business
What's worse - hiring the wrong person or not hiring anyone at all? Companies can become almost des - Joel Comm Is Dr. Adsense
What is Adsense? If you are new to making money online and net marketing, you may not know what Ads - 5 Steps For A Dynamic Wealth System Online
Recipe: Opportunity + knowledge + Dynamic Wealth System + Your Action = Massive Success!!! Step 1 - How To Stop Foreclosure
Losing your house to a foreclosure can be very scary. There are times when circumstances are ou - How to Always Pitch A Strike
As business owners, we are always working on new ways to convince people to become customers, client - Membrane Diffuser Solutions for Wastewater Treatment Systems
In the aeration basin of a typical wastewater treatment plant there are both organic and inorganic m - Another Year Hating Your Job or Loving Life?
Copyright © 2007 Mary Foley I've come to the conclusion that to be successful - really successf - Dyestuff Industry In India And China
World demand for dyes and organic pigments to touch $10.6 billion in 2008According to a study on dye - Cma-cgm Case : the Series of Lawsuits Continues in Syria, Lebanon, Egypt, France, England and the United States
Damietta company case : The series of lawsuits continues in Syria, Lebanon, Egypt, France, England a