Six Sigma Lean - Coursework Example

LEAN SIX SIGMA Growth of world manufacturing has created a need to measure elimination of waste through use of tools, techniques and methodology that would enable business to manage overproduction, defects in products, waiting time, inventory and other connected with the production processes. Thus, a method of Lean manufacturing is used to enable world businesses to remain at the competitive edge in the rapid growing global market. The central idea that stands behind the Six Sigma is to improve the quality of the process by removing the defects of the products in manufacturing. With the main idea of Lean and Six Sigma to create value based on the final requirements of a customer, Lean Six Sigma’s importance cannot be underestimated. The purpose of this report paper is to describe the Lean Six Sigma, a methodology that stand behind it, its tools, practices and fields for development. Lean Six Sigma Methodology According to Siddh, Gadekar, Soni and Jain (2013), Lean Six Sigma can be more detailed using DMAIC methodology composed of such phases as Define, Measure, Analyze, Improve and Control. During the phase of Define, all customers’ needs are taken into consideration and there is an established a connection between the Suppliers, input, process of manufacturing, output and customers. This phase enables to understand the main customers’ demands. During the measure phase (Siddh, Gadekar, Soni & Jain, 2013), it is necessary to gather quantities and qualitative data in order to obtain accurate current situation. Whether the gathered data is gathered to be used, an organization may start change the elimination waste process and issues connected with the methodology. The Analysis phase enables organization to use numerous analytical technologies to understand the cause of the problem and waste. However, Six Sigma is a technique in itself while Lean manufacturing has different analytical and statistical techniques. While Lean manufacturing is aimed to eliminate waste, according to Siddh, Gadekar, Soni and Jain (2013), together with the Six Sigma it created the synergy effect and a powerful tool. The Improve phase means that both Six Sigma and Lean manufacturing can be changed and particular resolution is formed on the basis of defects and waste, which were analyzed during the previous phase. The phase of Improve is aimed to implement a resolution in manufacturing method and ensure the elimination defects and waste. The phase of Control manages implementation of improvements. It manages constant process and reports on the variation if they occur. During this phase Six Sigma uses statistical process control. Lean manufacturing keeps waste minimal through use of 5S, where it controls sort, store, shine, standardize and sustain lean manufacturing. What is important is the strong side of Six Sigma while analyzing waste, as it uses statistical data. Tools The 5S tool is the most often used in the Lean manufacturing, which takes into account concerns with the cultural change, systematic and standardized processes normal routine. It is deemed equally in use to the show floor and office and is considered as the basis in obtaining a lean business (Pepper & Spedding, 2010). During the Six Sigma DMAIC methodology, each phase has its tools such as statistical process control, methodology of response surface and tool box of techniques. There are also Six Sigma tools that can be used to help with the task achievement. Thus, according to Pepper and Spedding (2010), it can be used along with the comprehensive methodology joining the main elements of Lean and Sis Sigma and follow the road map to define, measure, analyze, improve and control. The tools are the Data collection and analysis tools, Data collection tools and techniques and Seven management tools. The use of lean tools and techniques explain the leveraged by Six Sigma techniques areas. During the problem solving process, the Six Sigma tools are also used. Thus, according to Koripadu and Subbaiah (2014), among the well-known tools there are the Ishikawa diagrams, the Pareto Chart and Why analysis. Sokovic et al (2008) state about the Flow chart, Check sheet, Control chart, Histogram, Scatter plot and Cause and effect diagram. Thus, Pareto chart enables organization to understand the cause of the problem of waste and after isolating and correcting the main issues, it will obtain the increase in efficiency in the process of manufacturing. The Lean production provides with the other tools useful to eliminate waste (Exploring the world of lean, 2015). While 5S sorts, sets in order, inspects, write standards and applies these standards on the regular basis, there is Andon tool that enables organization to provide feedback for the plant floor about the production status; it also alerts when there is a need in assistance and gives employees an opportunity to stop the process of production. Bottleneck analysis helps to define the part of manufacturing which limits the process and its overall throughput, assisting at the same time in improving the performance. Gemba tool is useful in taking certain actions as to the problem resolution at the place where it happened. Another Lean tool is the Policy deployment or Hoshin Kanri tool that aligns company’s strategy with the tactics and action of the management and plant floor. Practices Best practices of Six Sigma and Lean manufacturing are aimed to improve company’s performance. To eliminate waste in manufacturing, there is a need to deploy a mechanism of recording, storing, viewing and reporting on the ongoing processes. Thus, Standardized work is used to document procedures. It is recorded and kept in case if it is needed. It will enable organization to track the improvement and control process of Lean manufacturing. In addition, there is a need to identify what the consumer needs and then use such information to improve experience. To eliminate waste, it is useful to view use-generated content, such as focus groups, feedback and surveys. Organized data in forms of diagrams, structure trees and charts will allow the company to ensure the DMAIC processes to be conducted in accordance with the company’s demands. The report process should be conducted in the regular basis (Best practices: project management and tracking tools, 2015). The vivid example of how best practice of Lean Six sigma is used is the waste reduction of Xerox Company. There is a need to reduce the environmental influence of the business, hence, Lean Six Sigma leads to the improvement of the company’s longstanding and its success (Lean Six Sigma, 2011). Shortcomings Despite the importance and complexity of implementing of Six Sigma in the manufacturing organization, there are still main hurdles in its successful implementation, according to Fursule, Bansod and Fursule (2012). The limitation is connected with the quality information and Six Sigma structured improvement procedure, which does not have a serious impact on the process management; however, influences Six Sigma focus on metric. Six Sigma is the repackaging of QM methods and it provides the new way for improvement quality and organizational excellence. Among other shortcomings of Lean manufacturing and Six Sigma is that Lean manufacturing is expensive in its implementation, questionable flexible, while the Six Sigma is structured. The most, however, disadvantage of Six Sigma is that as it is applied to all production and planning processes, it can develop rigidity and bureaucracy and thus cause delays and stifle creativity in the manufacturing. Moreover, there is a possibility to take customers’ focus to the limit, which will cause the internal quality-control measures. According to Lean Six Sigma Methodology (2015), there are possible shortcomings of Lean Six Sigma, the most important is the involvement of major changes to the workplace, where for instance the Lean implementations are not successful since management underestimated the time and efforts for implementation. In addition, Lean and Six Sigma can provide conflicting answers and then system needs to solve such differences and address then situations where conflicting areas will be championed. Lean Six Sigma methodology can cause wrong method for the problem solving. Thus, Six Sigma is not appropriate for resolving small problems with the great numbers of variables. Lean techniques are more effective in solving such small issues. While Lean Six Sigma represents the management approach that provides improvement and drives innovation, it also decreases the process variation. Conclusion With all the positive aspects of Lean Six Sigma approach, the application of this methodology will be more suitable for bigger companies and focus on the results and not on the implementation and the tools chosen for needs, goals and organizational structure. However, this combination helps companies to eliminate waste. While the purpose of this paper was to present the Lean manufacturing and Six Sigma technique and their methodology and tools, there appears a conclusion that using such techniques, companies are able to give the highest level of work duties, recognize its management, provide effective workplace and influence the duties of the employees. Six Sigma has a positive impact on the waste reduction and thus operational efficiency. Despite limitations of the techniques, Six Sigma is able to provide an organizational structure not seen in the past. References Best practices: project management and tracking tools, (2015). More stream, Retrieved from https://www.moresteam.com/resources/project-best-practices.cfm Exploring the world of Lean, (2015). Lean production, Retrieved from http://www.leanproduction.com/top-25-lean-tools.html Fursule, N., Bansod, S. and Fursule, S., (2012). Understanding the benefits and limitations of Six Sigma methodology, International Journal of Scientific and Research Publications, Vol. 2, Iss. 1, Retrieved from http://www.ijsrp.org/research_paper_jan2012/ijsrp-jan-2012-32.pdf Koripadu, M. and Subbaiah, K., (2014). Problem solving management using six sigma tools and techniques, International Journal of Scientific & Technology Research, Vol.3, Is. 2, Retrieved from http://www.ijstr.org/final-print/feb2014/Problem-Solving-Management-Using-Six-Sigma-Tools-Techniques.pdf Lean Six Sigma, (2011). The Report of Global Citizenship, The official website for Xerox Company, Retrieved from http://www.xerox.com/corporate-citizenship/2011/customer-experience/lean-six-sigma.html Lean Six Sigma Methodology, (2015). Graphicproducts, Retrieved from http://www.graphicproducts.com/articles/six-sigma-methodology.php Pepper, M. and Spedding, T., (2010). The evolution of lean Six Sigma, International Journal of Quality & Reliability Management Vol. 27 No. 2, pp. 138-155, Retrieved from http://metalab.uniten.edu.my/~rosnafisah/CISB524/Articles/The_evolution%20of%20six%20sigma.pdf Siddh,M., Gadekar, G., Soni, G. and Jain, R., (2013). Lean Six Sigma Approach for Quality and Business Performance, Global Journal of Management and Business Studies, Volume 3, Number 6, pp. 589-594, Retrieved from http://www.ripublication.com/gjmbs_spl/gjmbsv3n6_04.pdf Sokovic, M. et al, (2008). Basic quality tools in continuous improvement process, Journal of Mechanical Engineering, 55, 5, Retrieved from http://lab.fs.uni-lj.si/labod/documents/2014/ZK/ZK14%20Dodatno%20gradivo.pdf Read More