For example, if there are delays within a process, then by speeding up the process, the defect may be eliminated. However, this may be at the cost of quality if it is not given consideration. Here is where Lean can be useful by using the seven wastes theory. Additionally, defects will be reduced when the problem is solved.
The Six Sigma DMAIC method relies on the analysis of the problem and may not be able to provide solutions to real life problems. Thus, if you combine the two, Lean and Six Sigma you may have good solutions to rely on.
Lean Tools in Six Sigma Projects
Defects based on Lean wastes are rejects, movement, inventory, over processing, over production, transportation and waiting for the next step. In addition, it provides 5S, value stream mapping and error proofing, which in conjunction with Six Sigma can help sort out real life issues easily.
Let us take the example of the assembly of printed wiring board components (PWB). The process of assembling these components is a very complicated one and faces the critical problem of failure at the final product test.
The assembly, being complicated, is prone to defects and errors that could have caused further delays in shipping and rework. The Lean Six Sigma team in this case should focus on understanding the PWB components assembly area. If this is done, they will find three areas of errors, Manual insertion, automated insertion as well as semi-automated insertion.
Kitting errors, wherein all components are not provided as a common kit, can be identified. Other errors may also occur, such as layout of the manual insertion workstation and positioning the axial lead parts on the automatic insertion machine. The problems can be prioritized and further action taken.
The Lean way to problem solving can help overcome this situation so that improvements can be realized for a longer period. To achieve great results, Lean methodologies and Six Sigma phases can be combined.
By considering and implementing brainstorming sessions and the seven wastes in the Define phase of DMAIC, teams find it easier to define the problem area and develop creative solutions to the problem. In the Measure phase, teams can use Lean tools such as value-added to non-value added ratios, CT over Takt time and so on - and collect and measure the data related to the problem area.
In the Analyze phase, value stream mapping and the reframing matrix can be effectively used to look at the problem from different view points and prioritize those which need immediate attention.
In the Improve phase, the usage of 5S and other tools like the visual factory concept can help in sorting out problem areas and finding a different approach, if other approaches have been rejected. In the Control phase, error proofing is extremely useful to put controls in place to avoid errors in the first place.
Lean and Six Sigma provide creative solutions to solving real-life issues by precisely pointing out the errors and providing different ways to eliminate them. The data- driven approach of Six Sigma and the Lean way can work wonders for businesses.
Lean Six Sigma Dmaic
Analysis of a failed project will definitely help the team to know about the lack of commitment as well as attention by senior management, and towards the business and cultural investment that were required for accomplishing and sustaining the new levels of performance. It is here that the assessment will be needed when reworking a failed project, because it will reveal the exact nature of flaws.
Assessing The Various Deployment Stages Of Six Sigma
One of the most important things to remember in the implementation process is assessing the status quo at various intervals. Assessing a process will reveal any deviations if done from the intended line of progress. As it is known, process optimization and control are needed to render progressively higher quality in the deployment process. Performance efficiency and timeliness are also important, which is why a system of assessment needs to be put into place as an appropriate set of balances and checks to control all these factors.
No Two Six Sigma Assessment Procedures Can Be Same
No single assessment procedure developed by an organization can be applied to any other organization, or for even any other process for that matter. Companies that are successful in their own right have always developed their own assessment procedures. In fact, some of them have even used their internal audit system along with their own criteria in assessment. And even if you are using audit procedures developed by a reputable company like Motorola, it will still not be new or unique. Therefore, many organizations have gone ahead with evolving a custom developed audit system for their very own assessment procedures.
The Categories In Six Sigma Assessment Procedures
The most basic function of an assessment procedure is to understand the gap between "as is" and "what it should be" state of the process stage. The "should be" list indicates at the points decided in the very starting. There are categories for all processes including:
*Leadership
*Communication and implementation in day to day activities
*Project performance competency and effectiveness
*Organizational transformation
*The impact of the customer on processes
These top-level categories have different requirements to fill in to achieve the objectives completely. The assessment method used in this category includes written tests and interviews of top level managers all the way down to line employees, along with other meetings and seminars.
The overall results that are shown are applicable only to core business areas. In addition, the leadership assessment's results also show possible areas of weakness and areas for improvement. In fact, these results help in drawing up a course correction plan. The results will also indicate the weaknesses that should be assessed as the first steps of fine-tuning processes needed for the changes.
The best thing about assessment procedures is that it can be warranted whenever needed. In normal conditions where results takes 4-6 weeks to show, the best course of action is to schedule the assessment procedure as an annual routine exercise. If you observe the implementation procedure of successful Six Sigma techniques, then you will automatically realize that the major bottlenecks in changing the organization's mindset lies in sustaining whatever gains that are made to date.
Tony Jacowski has sinced written about articles on various topics from University, Six Sigma and Information Technology. Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solution's Six Sigma Online offers online and certification classes for six sigma pro. Tony Jacowski's top article generates over 90500 views. to your Favourites.
