Example Lean Six Sigma Projects In Manufacturing

[Suresh Jayaram]

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 levels

e) Improve customer service performance scores

f) Reduce cost of manufacturing & assembly (supplier component costs)

g) Reduce maintenance costs (better processes)

h) Reduce warranty costs for products

i) Improve customer satisfaction scores

j) Reduce the cost of non quality

k) Reduce non-value added activities (manufacturing steps)

l) Improve equipment utilization (improve throughput)

m) Reduce work-in-process inventories between processes

n) Improve inspection procedures (sampling techniques)

o) Reduce time to meet customer requirements

p) Reduce time to develop new products (manufacturing related)

q) Improve workplace organization

r) Improve process stability / control

s) Reduce variation in manufacturing quality

t) Standardize workplace

u) Deploy process flow concepts

v) Improve employee engagement scores

w) Improve product performance by controlling critical features

x) Improve planning & forecasting of demand (supply chain issues)

y) Reduce the amount of obsolete inventory

z) 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]

Hello,

 

Please through some light how we can improve delivery rating at our customer end.

 

regards

Mahi

 

 

 

[Suresh Jayaram]

Hi Mahi,

Are you talking about how to improve on-time delivery of products/services to your customers?

SJ

[Akhilesh Gupta]

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]

Six Sigma Projects in Manufacturing may be Identified which have an impact on OPEX.

Process Cycle Time Improvement

Appriasal Cost Reduction

Consumable Cost / Over Head Cost reduction

Equipment Efficiency Improvement

Variable Manpower Deployment reduction

Common Utility Cost Reduction

Reoccuring Rework Reduction

 

Pradeep

[Sarang Bhusari1314164370]

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]

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]

Dear sir

first 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 this

with regards

NATARAJA

[email protected]

[venkatesh n]

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 procedure

can anyone help me out

Regards,

Venkat

[CHIRAG KUMAR GUPTA]

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]

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]

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]

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]

Thanks everyone. Excellent in put for opn man.

Best

wishes.

Dr.R.V.Jayathirtha.

[jomygeorge787]

Can anybody elucidate on the term "Focused Improvement" in Manufacturing?

[Vishwadeep Khatri]

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]

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.â€

 

Objective of Lean is to increase process speed and reduce invested capital. 

Lean philosophy:

“One piece at a timeâ€

“Synchronized flowâ€

“Pull Systemâ€

“Eliminate waste†in the value stream

 

Objective of Six Sigma is to reduce variation

 

Metric:  Measure process variation 

 

Methodology :

Consistent use of DMAIC/DMADV model

Team based problem solving,Measurement-based process  analysis, improvement and control

 

Management System 

Six Sigma drives strategy execution 

Leadership, sponsorship and review

Metrics driven governance process

Engagement across the organization 

 

 

 

 

 

 

[Viswanathan_Muthu]

Thanks for the post.

quite a lot of applications.... brought a lot of clarity...

[Arunkumaar PM]

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]

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.]

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 procedure

can anyone help me out

Regards,

Venkat

Dear 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]

Hi All,

 

Please share some six sigma or lean project in paper industries.

[Guest Vijay Mohnani]

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]

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]

Hi Vibhanshu, 

 

Have you gone through some structured learning on Lean Six Sigma so far? Have a look at