“Modern Machine Shop” published an
article last spring that highlighted the use of Lean and Six Sigma concepts with
companies to help improve their processes.
You will see a lot of these concepts in the manufacturing sector, but
one could also find these methods in other industries such as agriculture,
transportation, or food and beverage.
Basically, the overall goal for both methods is to eliminate waste and
defects by using the most efficient methods to improving a company’s
performance.
These two topics can really help
you break down manufacturing processes through more cost-effective habits of
production. Many people probably don’t realize
how wasteful you can be when producing or making things. A disorganized tool box, overproduction of
finished goods, unsold products, and waiting on delivery of your bill of
materials are all considered wastes in a manufacturing environment. Figure 1 represents the 8 wastes of Lean that
need to be eliminated.
Photo credit: https://lean6sigma4all.eu/lean-management-and-the-8-wastes/Most people hate throwing food away from their fridges before they get to eat it. We often make more than we can eat, and therefore “leftovers” could be considered waste. Now, if you made smaller portions for dinner, you could virtually eliminate what you throw away into the trash. This is a simple, but relevant at home experience that you may have faced. Cooking smaller portions in this case would classify as a process that you would perform to become more of a “Lean” cook. I’m sure you can come up with several other situations that are comparable to this one in your day to day lives.
I spent six years in the U.S. Army
and I have been in the manufacturing sector for seven years now. During these times, I have witnessed the
implementation of Lean and Six Sigma practices.
Often you don’t even realize these concepts until it’s brought to your
attention. One of the greatest tools I
think that manufactures need to do, is to incorporate a 5S program. This universal method for obtaining workplace
organization is both helpful and appealing when on the floor of any
manufacturing facility.
I have been in some factories where
you could literally eat off the floor because it was so clean. Besides being squeaky clean, everything had
its own what I call, “home”. Every tool,
broom, pallet jack, ink pen, SOP book, workbench, you name it, had its own
place and was clearly identified. This
is critical because everybody could find what they were looking for, and then
when done with that item they could return it to its labeled area. 5S will ultimately improve safety, productivity,
and can help eliminate waste.
Six Sigma in my opinion is
awesome! I say this because a few weeks
back I got into a really good book that refreshed my mind with jam-packed information
concerning this topic. One of the most
useful tools that I have found is called “5 Whys”. The overall goal is to determine the root
cause of a problem or situation. By
asking “Why?” to yourself or others, you should successfully be able to
determine the root cause because each question leads to the beginning of the
subsequent question.
Continuous improvement is a concept
that a lot of manufactures strive and live for, but you can also see it
demonstrated in other industries as well.
Your company can surely experience the benefits when you begin to
incorporate some type of Lean and or Six Sigma programs. Who doesn’t want to eliminate waste and
become more proficient in their processes?
Anyone who has thrown away last week’s leftovers from their fridge will understand.
Link to article:
Resources:
George, M. L., Rowlands, D., Price, M., & Maxey,
J. (2005). The Lean Six Sigma Pocket ToolBook. New York: McGraw-Hill.
Manufacturing Skill Standards Council. (2006). High-Performance
Manufacturing. Woodland Hills: Glencoe/McGraw-Hill.
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