Lean Management

Improving productivity rate by reducing wastes.

Value, value stream, flow, pull and perfection are the main principles
of lean management.
Never ending process of development to achieve more and more
profits.
Achieving customer demand by giving them desired quality
products
Good quality production in minimum time and wastage.

Lean Techniques

Value Mapping
Single Minute Exchange of Dies
Single Piece Flow
Inventory Control via Card System
Concept (Separate, Self discipline, Simplify, Standardize, Sustain)
Total Productive Maintenance
Visual Management
Production Line Optimization

Key issues of lean management

Supply chain issue.

Employee development.
Technological challenges.
Cultural issues.

Six Sigma

Improve the quality of the output of a process by identifying and

removing the causes of defects
Minimizing variability in manufacturing and business processes.
Continuous efforts to achieve stable and predictable process results

Methodology

DMAIC is used for projects aimed at improving an existing business

process.

Define the system, the voice of the customer and their

requirements, and the project goals, specifically.
Measure key aspects of the current process and collect
relevant data; calculate the 'as-is' Process Capability.
Analysis the data to investigate and verify cause-and-effect
relationships. Determine what the relationships are, and
attempt to ensure that all factors have been considered. Seek
out root cause of the defect under investigation.
Improve or optimize the current process based upon data
analysis using techniques such as design of experiments,
poka yoke or mistake proofing, and standard work to create a
new, future state process. Set up pilot runs to establish
process capability.
Control the future state process to ensure that any deviations
from the target are corrected before they result in defects.
Implement control system such as statistical process control,
production boards, visual workplaces, and continuously
monitor the process.
DMADV is used for projects aimed at creating new product or
process designs.
Define design goals that are consistent with customer
demands and the enterprise strategy.
Measure and identify CTQs (characteristics that
are Critical To Quality), measure product capabilities,
production process capability, and measure risks.
Analysis to develop and design alternatives
Design an improved alternative, best suited per analysis in
the previous step
Verify the design, set up pilot runs, implement the production
process and hand it over to the process owner(s).

Issues with Six Sigma

Lack of committed leadership

Too many improvement initiatives
Confused executives
Resistance to change from event driven to process driven mindset
Lack of standard training material including software
Lack of systematic project selection, execution & review
Lack of continuity/sustenance in implementation