Wednesday, January 17, 2018

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Lean and Six Sigma

Lean and six sigma are process improvement strategies to reduce waste and increase quality in business processes.

What is Lean Manufacturing?

Lean, is the manufacturing and organizational process that Toyota and other Japanese manufacturers have used to fundamentally change the automotive industry.  It is the Toyota Production System (TPS). Lean is best characterized as a systematic approach to the identification and elimination of Waste (MUDA) or Non-value Added activities through continuous improvement. 

What is Six Sigma?

Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes. The maturity of a manufacturing process can be described by a sigma rating indicating its yield, or the percentage of defect-free products it creates. A six sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defects per million). Originally developed by Motorola, Six Sigma can be applied to any business process that can benefit from waste reduction.

Why Hire PMC for Your Lean and Six Sigma Needs?

For over 30 years, PMC has applied Lean and Six Sigma methods and tools to improve the productivity and quality of its clients' business processes. PMC initially deployed its Lean and Six Sigma capabilities in the automotive industry, and expanded its consulting and training services to include service industries such as construction, healthcare, and financial services. What makes PMC unique is the breadth and depth of consulting and training expertise in all the methods and tools used with Six Sigma and Lean Manufacturing.

Typical Lean Methods we use:
  • Value Stream Mapping
  • Error Proofing (POKA YOKE)
  • KANBAN (Pull systems)
  • Quick Setup (SMED)
  • Reduction of Variation (Six Sigma)
  • Standardized Work
  • Supplier Development
  • Workplace Organization and Visual Controls (5S)
Partial List of Tools we use for Lean Manufacturing:
Six Sigma Methods we use:
  • DMAIC (Define, Measure, Analyze, Improve, Control) - is used for projects aimed at improving an existing business process.
  • DMADV (Define, Measure, Analyze, Design, Verify) or DFSS (Design for Six Sigma) is used for projects aimed at creating new product or process designs.
Partial List of Tools we use for Six Sigma:
  • Analysis of Variance (ANOVA)
  • Control Charts
  • Design of Experiments
  • Failure mode and effects analysis (FMEA)
  • Process Mapping
  • Regression Analysis
  • Root Cause Analysis
  • Taguchi Methods
Benefits of PMC's Lean and Six Sigma services include:
  • Increased productivity
  • Reduced cycle time
  • Reduced inventory
  • Efficient material flow
  • Reduced floor space requirement
  • Improved understanding of customer requirements
  • Agility to respond to changing customer requirements

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