Manish Gupta2020

In OEE there are traditional 6 big losses: Equipment Failure Setup & Adjustments Idling & Minor Stops Reduced Speed Process Defects Reduced Yield They can be grouped further: Availability Loss Equipment Failure Setup & Adjustments Performance Loss Idling & Minor Stops Reduced Speed Quality Loss Process Defects Reduced Yield Few ways in which we can avoid/ reduce these 6 big losses Equipment Failure – Avoid Tooling Failure, breakdowns, unplanned maintenance. Keep material ready so that machine is not starved by upstream equipment or being blocked by downstream equipment. Eliminate unplanned downtime. Setup & Adjustments – Changeover – Time between the last correct unit until the first correct unit has been produced after the changeover. Keep necessary tools or parts needed for changeover ready or within reach Idling & Minor Stops- Where machinery ceases to operate for very small duration like 1-2 minutes because of any reason. Do minor cleaning activities, reduce misfeeding, diminish incorrect configurations, lessen material jams Reduced Speed - Compare all cycles times with ideal cycle time. Operator experience should be considered for any change, worn-out equipment should be replaced, avoid low quality material or lessen environmental effects. Process Defects – Manage your equipment settings, operator knowledge or equipment handling Reduced Yield - Reduce Sub-optimal changeovers, Incorrect settings, keeping equipment warmup to required cycles etc https://www.novotek.com/uk/solutions/overall-equipment-effectiveness/explanation-of-the-six-big-losses/ https://www.oee.com/oee-six-big-losses.html

Application of Six Sigma goes beyond process correction & improvement. Some real powerful tools to detect fraud in accounting are utilized by organizations to ensure they remain profitable in business. 1. Tools/ processes are used to find anomaly in the system 2. Find frequencies of these errors. Financial Fraud can happen at lot of places e.g. 1. Money Laundering 2. E-Comm transactions 3. Credit Card 4. Insurance & Health transactions 5. Subscription fraud One useful tool can be use of Benford Law…This law uses principle that frequency distribution of 1st digit from numerical data of processes should align to discrete distribution which is called Benford distribution.

At the time when Taichi Ohno started Andon Card in Toyota and gave permission to all employees to immediately halt production when they notice any problem. The concept was considered crazy by all. Initially people ignored it but managers who implemented it where producing more cars with better quality. Stopping the Line causes 1. Timeline issues 2. Lost revenue 3. Unpredictable supply Few Benefits are 1. Process Improvement 2. Improved Quality 3. Increased employee engagement 4. Prevents problem accumulation In order to minimize the impact 1. Keep the communication process in place 2. All Hands on deck system 3. Place Early warning system 4. Go to the Gemba “War Room” 5. Limit downstream impact 6. Genchi Genbutsu - Means go and see for yourself. Go see the problem. 7. Pro-active thinking 8. Fast Implementation process