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Lean Six Sigma manufacturing is widely used in the manufacturing units. Many popular companies from all over the world have reaped the benefits of this method. The practice of Lean is quite old in the manufacturing field. But the Six Sigma tools were incorporated into it so that the statistical approach can be used remarkably. The experiment proved successful and the results can be observed in enhanced customer satisfaction and improvement in overall quality of products. Lean Six Sigma manufacturing is a fusion of the lean methodologies and Six Sigma management strategies. This combines methodology aids in improving the overall output of the processes. In other terms, Lean Six Sigma Manufacturing can also be described as solving the complicated problems of manufacturing industries using the Six Sigma and lean techniques. The relation between these two different methodologies is described in several ways like: - Extending the Six Sigma process using the techniques of lean.
- If there is a problem where the desired standards are not met in a particular process, it can be solved easily with these combined strategies.
- The Six Sigma techniques are utilized to retain the improvements made to the system.
- The specific problems of the manufacturing units can be effectively solved by Lean Six Sigma Manufacturing.
Application of Lean Six Sigma Manufacturing in the industries is a stepwise process and the steps are as follows: - Defining the Process: First of all, the problem areas of a process are detected and a project is planned observing the scopes of improvements. The next step is defining the goals of the projects to the employees and also to the management. This is essential because the senior management supports the system. The risks related to the project should be measured before implementing it. The problems are addressed and resolved according to the priorities.
- Analyzing the Problem: Tools like histograms and flowcharts help in chalking out the tasks to be performed throughout the process. Often, excel sheets are also used to categorize the data. The data driven approach of Lean Six Sigma Manufacturing aids in the analysis process. There are certain exclusive principles of Lean Six Sigma Manufacturing which ensure maximum output at reasonable turn- around time. These principles are: zero inventory and wait time, cutting the batch sizes, balancing the lines and scheduling.
- Innovative Ideas: The Lean Six Sigma Manufacturing strategies can be further improvised by implementing the innovative ideas. This particular process works quite well when the employees are included into it. Many of the popular companies have used this method and reaped benefits out of it. It is also known as brainstorming and brilliant ideas pour in on regular basis. The affinity diagrams are used to sort out the best ones from it.
- Implementing the Changed Strategies: The strategies that are chalked out after thorough analysis should be implemented carefully. Initially, the changes will show minimum yields and gradually it will increase to remarkable benefits. The value of stocks, customer feedback and revenues will increase noticeably as a result.
- Lean Six Sigma Manufacturing in Product Development: There are two steps followed before a product is finally generated- designing and final production. The collective effects of Lean and Six Sigma strategies help in both the stages, which ensure that the final product is flawless from all aspects. Moreover, it also helps the employees and supervisors learn the process practically, which proves beneficial in the long run. The defect level is reduced greatly, which is directly proportional to the customer satisfaction factor.
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