Lean Six Sigma is a method that focuses on improving performance by systematically eliminating problems, removing waste, inefficiency and improving the working conditions, thus creating a favourable working environment for better results to customer needs. The method incorporates the six sigma and the lean enterprise or the lean manufacturing to get of the eight main wastage such as excess production, waiting time. Non-utilized resources and talents, Inventory, motion, talent, and extra processing.
Lean Six Sigma focus not only on reducing production wastes but also on providing a platform for the overall organizational changes such as the business culture. The method changed the thinking perspective of both managers and employees from short gains to focusing on continues grown and improvement through optimization and efficiency adoption.
The overall impact of Lean Six Sigma is the midst and cultural change in an organization, thus maximizing the organization profitability in the long term and efficiency.
A combination of various tools from the Six Sigma and Lean manufacturing must be used to implement the Lean Six Sigma method successfully, and some of these tools include the value stream mapping, visual management, and kaizen.
Successful implement Lean Six Sigma requires a combination of tools from both the lean manufacturing and Six Sigma and some of these tools include kaizen, value-stream mapping, line balancing, and visual management. Lean Six Sigma combines various methods, tools and principles into a single powerful and popular methodology of improving the entire organization operations efficiency.
A team approach Lean Six Sigma has proved better results in maximizing the organizational production efficiency, hence dramatically increasing the organization profitability globally.
• What are Lean six sigma elements?
Tools and techniques.
These are a wide range of analytical techniques and a set of various tools that are crucial in recognizing problems as well as solving such challenges.
Procedures and approaches.
These are a series of phases and stages that an organization uses to organize its problem-solving tools. Thus ensuring the correct solution are applied to address the issues adequately.
Organizational culture and mindset.
It means the thinking perspective in an organization setup from managers down to employees and entirely depends on the data and processes to accomplish the organization goals and continuously keep improving the results.
• The Lean Six Sigma Background.
The Lean Six Sigma history explains how its different components and methodologies have been developing over time to become what is known as the Lean Six Sigma approach. What is Lean? The Lean manufacturing was developed in Japan by the Toyota Corporation as part of their production system and by the Deming and Shewhart work. The main focus of the methodology was to reduce product wastage.
• Types of waste based on Lean six sigma approach.
The following are the types of waste identified according to Fujio Chuo of Toyota. According to him, waste is anything else apart from the primary equipment materials, space. parts and workers time which are crucial in adding value to the final product
1. Defects. These are final products but do not meet the requirement to make fit for usage. The company has to scrap or rework them, which costs the company resources and time.
2. Over-production. These are a product that has been made in excess or made without immediate use, for instance, creating unnecessary products before customers have made an order for them.
3. Waiting. It involves a time when equipment ought to be productive, but they are idle or waiting for material to be approved by the managers, thus causing delays.
4. Non —Utilized Talents. It refers to the waste of human skills and potentials, such as when employees go to strikes and go slow due to differences between the management and the employee.
Another type of waste includes transportation and inventory delays as well as excessive motion in an organization.
What is the Six Sigma methodology?
Six Sigma approach was initially developed at Motorola Corporation. The United States in the year 1986 to complete Lean manufacturing. The methodology main goal was to eliminate production errors by improving the measuring, and quality systems worked. Bill Smith, who was the quality engineer pioneered Six Sigma, curb the Motorola manufacturing weakness that accepted a certain degree of errors in production, leading to the creation of too much rework, scrap, redundant testing and the overall quality compromise. The Six Sigma methodology much focused on removing any process that would otherwise cause variation from quality production.
• The five main phases of Six Sigma?
Here boundaries of the process being analyzed are set. And the desired expectations and performances of a process set based on the customer perspective, thus ensuring changes are not negating from the customer’s know-how but rather improve it.
The current performance of a process is measured to particularly from a customer perspective to get an analysis basis.
Applying the data measured, the source of variation causing the problems are measured, thus establishing the exact problem root cause.
here any possible changes in the product or the process are evaluated for designing a set of solution to these changes
In this stage, the desired changes are implemented as well as updating the supporting systems.
• What are the benefits of implementing Lean Six Sigma model?
Just as stated above. Lean Six Sigma focuses on a continuous process, product or service improvement. The Lean Six Sigma benefits are categorized into various components. namely:
Organizations focus on profit maximization by increased sales as a result of customer satisfaction, thus establishing reasonable customer satisfaction.
The Lean Six Sigma simplifies most of the business process since the methodology highlights areas of inefficiency and wastage. The erroneous process creates tedious work causing the persistent problem in an origination. Additionally wasted efforts worsens the situation as the organization management isn’t willing to pay while the employees are demanding for their effort irrespective it was constructive or not.
Fewer errors and mistakes. The Lean Six Sigma starts by defining the accepted quality from a customer perspective. Then the whole process principle on continuous improvement, thus avoiding repetition of past mistakes and errors.