Suresh Jayaram Posted January 30, 2009 Report Posted January 30, 2009 There are several areas in which Lean Six Sigma can be applied to manufacturing operations. Some examples are:a) Reduce quality defects (scrap/rework) in manufacturing processes.b.) Reduce manufacturing cycle time (time of order to delivery)c) Improve employee efficiency (productivity)d) Reduce finished goods inventory levelse) Improve customer service performance scoresf) Reduce cost of manufacturing & assembly (supplier component costs)g) Reduce maintenance costs (better processes)h) Reduce warranty costs for productsi) Improve customer satisfaction scoresj) Reduce the cost of non qualityk) Reduce non-value added activities (manufacturing steps)l) Improve equipment utilization (improve throughput)m) Reduce work-in-process inventories between processesn) Improve inspection procedures (sampling techniques)o) Reduce time to meet customer requirementsp) Reduce time to develop new products (manufacturing related)q) Improve workplace organizationr) Improve process stability / controls) Reduce variation in manufacturing qualityt) Standardize workplaceu) Deploy process flow conceptsv) Improve employee engagement scoresw) Improve product performance by controlling critical featuresx) Improve planning & forecasting of demand (supply chain issues)y) Reduce the amount of obsolete inventoryz) Improve related transactional processes: accounting, human resources, purchasing etc.Some of these projects are more suited for Six Sigma type projects, others are Lean type projects / processes, and some may require both Lean and Six Sigma toolkits.
Mahendra Bhandari Posted February 18, 2009 Report Posted February 18, 2009 Hello, Please through some light how we can improve delivery rating at our customer end. regardsMahi
Suresh Jayaram Posted February 19, 2009 Author Report Posted February 19, 2009 Hi Mahi,Are you talking about how to improve on-time delivery of products/services to your customers? SJ
Akhilesh Gupta Posted February 19, 2009 Report Posted February 19, 2009 Hi,we need to identify internally what are the reasons which are affecting the cutomer delivery. these can be the X's of our big Y i.e.delay in customer delivery.through data collection and analysis we need to identify few critical causes which are affecting most to this problem.
Pradeep Sharma1314164363 Posted February 19, 2009 Report Posted February 19, 2009 Six Sigma Projects in Manufacturing may be Identified which have an impact on OPEX.Process Cycle Time ImprovementAppriasal Cost ReductionConsumable Cost / Over Head Cost reductionEquipment Efficiency ImprovementVariable Manpower Deployment reductionCommon Utility Cost ReductionReoccuring Rework Reduction Pradeep
Sarang Bhusari1314164370 Posted August 3, 2009 Report Posted August 3, 2009 Dear Mr.Jayram,I am newly joined to this forum.I have done my MBA in Operations after Mech. Engg.I am currently working as a Mgmt. Trainee in a Manufacturing Company.Actually, I wanted to know the carrer path in this field with respest to Six Sigma.Also, what are the opportunities & challenges.Thanks & Regards,Sarang Bhusari
CHIRAG KUMAR GUPTA Posted August 3, 2009 Report Posted August 3, 2009 Dear Sarang, Welcome to the interactive forum of Benchmark Six Sigma. Following is the "web link" that will help you, in getting the knowledge of the "Career Path" of various Six Sigma practitioners in this industry. Here are some 'Success Stories' on the following URL; http://forum.benchmarksixsigma.com/blog/4-benchmark-six-sigma-blog/ Regards, Chirag Kumar Gupta
nata.mech Posted September 18, 2009 Report Posted September 18, 2009 Dear sirfirst of all i am interducing my self as a NATARAJ -SR QUALITY ENGINEER IN MANUFACTURING COMPANY. NOW i am planning to implement six sigma but i dont know how to start it so that i can get better results please could you help me to take decision regarding thiswith regardsNATARAJA [email protected]
venkatesh n Posted September 18, 2009 Report Posted September 18, 2009 Dear sir,since we are doing calibration for the new equipment,is it required to to the linearity study.what difference linearity study has with calibration procedurecan anyone help me outRegards,Venkat
CHIRAG KUMAR GUPTA Posted September 18, 2009 Report Posted September 18, 2009 Dear Mr. Nataraja, Six Sigma has a very significant use in Manufacturing Sector. You can find the way of applying 'Six Sigma in Manufacturing', in the following link (URL); http://forum.benchmarksixsigma.com/topic/839-six-sigma-targets-in-manufacturing/ Regards, Chirag Kumar Gupta
Gopinath TS Posted November 28, 2009 Report Posted November 28, 2009 I am T.S.Gopinath has joined recently the forum. I am Leansigma Black belt from GSK Pharmaceuticals and currently working as GM - Operations . In addition to Manufacturing i am also coordinating Lean Sigma activities in the company. To start with we have conducted Brain Storming sessions across all depts in the company and generated 1000 ideas for improvement , Selected about 50 Projects for implementation and getting cost benefits . The areas we have focussed are, 1) cycle time reduction 2) Waste in QC sampling 3) Waste in excess material in packing more than required 4) Waste in stationary 5) Recycling of packing material 6) Energy coservation 7) Water conservation 8) Yield improvement 9) Reduction in WIP material 10) Reduction in waiting time 11)Reduction in communication wastages 12) Reduction in transportation
janaki wadaskar Posted February 25, 2010 Report Posted February 25, 2010 If we have selected sixsigma project on Productivity improvement or reduce in cycle time what will become the lower specification limit? Regards,Janaki
Vishwadeep Khatri Posted February 26, 2010 Report Posted February 26, 2010 Dear Janaki, You should proceed with one sided specification limit in both the cases. For productivity you should have a lower limit, while for cycle time you should have an upper limit. Regards, VK
Dr.R.V.Jayathirtha Rotti Posted March 1, 2010 Report Posted March 1, 2010 Thanks everyone. Excellent in put for opn man. Best wishes. Dr.R.V.Jayathirtha.
jomygeorge787 Posted December 1, 2011 Report Posted December 1, 2011 Can anybody elucidate on the term "Focused Improvement" in Manufacturing?
Vishwadeep Khatri Posted December 2, 2011 Report Posted December 2, 2011 It is about bringing improvements in OEE (Overall Equipment Effectiveness). Also referred as Kobetsu Kaizen, the objective is to bring down various losses. For bringing these improvements, various Lean Six Sigma techniques need to be utilized suitably.
Somanathan Krishnamurthy Posted July 14, 2013 Report Posted July 14, 2013 Foundations of Lean principles can be traced back to Toyota Production System (TPS)Taiichi Ohno, the founder of TPS said:“All we are doing is looking at the time line from the moment the customer gives an order to the point when we collect cash. And we are reducing the time line by removing the non-value added wastes.†Objective of Lean is to increase process speed and reduce invested capital. Lean philosophy:“One piece at a timeâ€â€œSynchronized flowâ€â€œPull Systemâ€â€œEliminate waste†in the value stream Objective of Six Sigma is to reduce variation Metric: Measure process variation Methodology :Consistent use of DMAIC/DMADV modelTeam based problem solving,Measurement-based process analysis, improvement and control Management System Six Sigma drives strategy execution Leadership, sponsorship and reviewMetrics driven governance processEngagement across the organization
Viswanathan_Muthu Posted August 30, 2013 Report Posted August 30, 2013 Thanks for the post.quite a lot of applications.... brought a lot of clarity...
Arunkumaar PM Posted May 6, 2014 Report Posted May 6, 2014 Hi This is Arunkumaar PM. I am new to this forum at the same time I am new to the Market also ( Now only I completing my Journey of Education). I am planning to enter into the field of Materials in Particular Diesel Engine Manufacture. Can anyone tell me, what are the defects may come in Purchase department.? and tell me the way to reduce the defect....? Thank you
Vishwadeep Khatri Posted May 9, 2014 Report Posted May 9, 2014 Hi Arun, a requirement not met is a defect. So, for Purchase Department, an incoming non conforming material is a defect, non-conformities missed in receiving inspection is a defect, good material rejected is a defect, not following the specified procedure is also a defect. It is hard to specify an action to reduce defects at this point as your action shall depend on the kind of defect and the surrounding information that you can gather when you are at the workplace. Hope this helps.
Shivaramakrishna. Posted May 27, 2014 Report Posted May 27, 2014 Dear sir,since we are doing calibration for the new equipment,is it required to to the linearity study.what difference linearity study has with calibration procedurecan anyone help me outRegards,VenkatDear Mr.Venkat, If you are refering about the uncertainity test, this test is useful to determine the level of sesitivity of your equipment to the external factors. This test will give you information of what is the minimum level of defect your equipment can identify. This is also useful for determining your gauge R&R Regards,Shivaramakrishna
Javed Shaikh Posted January 6, 2017 Report Posted January 6, 2017 Hi All, Please share some six sigma or lean project in paper industries.
Guest Vijay Mohnani Posted August 2, 2017 Report Posted August 2, 2017 Dear Javed, In order to make "Lean Six Sigma Projects In Forestry & Paper Industry" clear to you. I would request you to please have look at this case study which will help you understand the Lean Six Sigma Projects in the paper industry. Please click on this link - https://www.benchmarksixsigma.com/lean-six-sigma-in-forestry-paper-timber-nurseries/ Hope this helps! Regards, VM
Vibhanshu Sinha Posted October 29, 2017 Report Posted October 29, 2017 hi all I am vibhanshu sinha and currently associated with a food industry.I have applied the concepts of SMED to reduce machine format changeover time at my workplace.I am interested in learning six sigma principles and its implementation for process improvement. Regards
Vishwadeep Khatri Posted November 3, 2017 Report Posted November 3, 2017 Hi Vibhanshu, Have you gone through some structured learning on Lean Six Sigma so far? Have a look at
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