Process of Waste Integration of Lean and
Process Improvement using Lean Six Sigma TechniquesAPerception of Indian SMEsContentIntroductionSixSigma and LeanApproaches of Lean and Six SigmaTypes of WasteIntegration of Lean and Six SigmaResults of LSSDifficultiesStatus Quo of Indian SMEsConclusionsReferencesQuestion and AnswerIntroductionSix Sigma The aim of Six Sigma is to reduce/control variationthrough statistical methods that lower process defect rates to less than 3.4 DPMO. Lean Lean is a series of tools and techniques to manage our organization’sprocesses. Specifically, Lean focuses on eliminating all non-value-addedactivities and waste from processes.What is LeanSix Sigma Lean Six Sigma Lean Six Sigma is amanagerial approach that combines Six Sigma methods and tools and the lean manufacturing philosophy, striving to eliminate waste, whileassuring quality in production and organizational processes. From all these definitions we decodeLean Six Sigma is a quality programthat, when all is said and done, improves your customer’s experience, lowersyour costs, and builds better leadersLeanWastesTransportation – Unnecessary movement of Products.Inventory – Unnecessary storage of Products.
Motion– Unnecessary movement of Men and Data.Waitingtime – Product Waiting for any process.Overproduction – Producing large number of Productsand keeping it in warehouse.Overprocessing – Processes those do not add value tothe quality (NVA)Defects – Incorrect work that must be donecorrectly to achieve quality How Six Sigma deals with variation How Six Sigma dealswith Defects A Six Sigma process produces 3.4 DPMO thatmeans literally no defects.
Integration of Lean and Six SigmaTheeffectiveness of two techniques, Six Sigma and Lean production has beencombined into LSS. LeanSix Sigma changes the way the company thinks Lean manufacturing – increases the speed of process – removes wasteSixSigma – controls Variation – Quality demand is achieved.Status quo of Indian SME’s1.Never heard of Lean SixSigma.2.LeanSix Sigma is nothing new, just like TotalQuality Management.3.Nothaving time for a Lean Six Sigmaprogram.
4.Costsof implementing aLean Six Sigma program.5.
We’retoo small. LSS is forlarge companies.6.LeanSix Sigma involves alot of statistics and advanced mathematics.
Most of our employees arefront-line operators — not engineers.7.Fearof the unknown or failure8.We’renot a manufacturer.
How Lean Six sigma benefited CompaniesSome of the Industry samplesFord Motor Company Six Sigma enabled Ford Motors to eliminatemore than $2.19 billion in waste over the last decade and half.Result of LSSProfitis a function of costs minimization and sale volume and this can be expressedas equation below: P=f(CM+SV)ConclusionIndustrysector being the second biggest contributor to the GDP it is essential to applyLean Six Sigma and it can be applied to services like Hospitals, Airports. Differentorganizations have different maturity levels of QM implementation and theirexisting QM systems vary.Beyondany doubt LSS is far more than other Traditional Quality Management Techniques.References1.Mohamed K.
Hassan,Applying Lean Six Sigma for Waste Reduction in a Manufacturing Environment,American Journal of Industrial Engineering, 2013, Vol. 1, No. 2, 28-35.2.Nilesh V Fursule, Dr. Satish V Bansod, Swati N. Fursule, Understanding theBenefits and Limitations of Six SigmaMethodology, International Journal of Scientific and ResearchPublications, Volume 2, Issue 1, January 2012 1ISSN 2250-3153.3.
M.P.J. Pepper andT.A. Spedding, The evolution oflean Six Sigma, International Journal of Quality & Reliability Management,Vol. 27 No.
2, 2010 ,pp. 138-155, Emerald Group Publishing Limited, 0265-671X,DOI 10.1108/02656711011014276.4.
Hamad Mohammed Abouhenidi, How to reduce wasteon Industries by using Lean Six Sigma Tool, International Journal of Scientific& Engineering Research, Volume 5, Issue 8,August-2014 ISSN 2229-5518.5.Harsimran Singh Sodhi1, Doordarshi Singh2, Bikramjit Singh3,Lean and Six Sigma: A Combined Approach for Waste Management in Indian SME’s,International Journal of Latest Technology in Engineering, Management &Applied Science (IJLTEMAS), Volume VI, Issue V, May 2017 | ISSN 2278-2540.6.
Rajeev Rathi1, Dinesh Khanduja2,S.K.Sharma3,Six Sigma Perceptions for Capacity Waste Management in Indian ManufacturingSector, Journal of Material Science and Mechanical Engineering (JMSME), PrintISSN: 2393-9095; Online ISSN: 2393-9109; Volume 2, Number 7; April-June, 2015pp.
36-40.7.Okpala Kenneth Enoch, LeanSix Sigma Methodologies and Organizational Profitability: A Review ofManufacturing SMEs in Nigeria, American Journal of Industrial and BusinessManagement, 2013, 3, 573-5828.
Roy Andersson, Henrik Eriksson and Hakan Torstensson, Similarities and differencesbetween TQM, six sigma andlean, The TQM MagazineVol. 18 No. 3, 2006pp.282-296. 9.Thomas, A., Barton,R.
and Okafor, C. C., ApplyingLean Six Sigma in a small engineering company a model for change, Journal ofManufacturing Technology Management, 20 (1): 113-129, 2009. 10.
Melton, T., TheBenefits of Lean Manufacturing What Lean Thinking has to Offer the ProcessIndustries, Chemical Engineering Research and Design, 83 (A6): 662-673, 2005. 11.Abdulmalek, F.A and Rajgopal, Analysing theBenefits of Lean Manufacturing and Value Stream Mapping via Simulation; aProcess Sector Case Study, International Journal of Production Economics, 2007.12.Larrabee, D.
T and Voss J.A.Valuation Techniques: Discounted Cash Flo, Earnings quality, Measures of ValueAdded activities and Real Options, John wiley & sons, 2012.
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A, Review onReduction of Delay in Manufacturing process using Lean Six Sigma Systems,International Journal of Scientific and Research Publications 2013.14.Prieto C, Navarro R andGonzalez A, Reduction of Waste by Combining Lean Manufacturing and Six Sigma inan Electronics Industry, Research Journal of Applied Sciences, Engineering and Technology, 2014.15.S.B.
Akpan, I.V. Patrick, D.E.John S.J, Udoka, Analysis ofEconomic Capacity Utilization in the Nigerian Sugar Industry (1970- 2010),Journal of Department and Agriculture, 2013. ????