Companies around the globe have saved millions and even billions of dollars in the past few decades by integrating Lean and Six Sigma techniques into their systems.
In this blog, we will discuss the top lean tools and their applications that can help any organization create an effective process.
Introduction to Lean Six Sigma
Lean Six Sigma had its roots in Motorola and the electronics agencies. It was developed in 1986 as a defect-reduction technique.
It has an excellent record of being widely extended through many sectors. Lean Six Sigma has used information technology, banking, manufacturing, hospitals, insurance, and even the military to turn systems of enterprise process management concepts – often being the secret to keeping competitive in today’s busy marketplace.
It is the convergence of two different ideas, combined to create a dynamic method for changing the laws of the industry. Lean Six and Sigma.
Examining LEAN
There are a lot of big plans to determine lean.
One way to start is to survey the most important lean tools, with a brief description and a short explanation of how each device can improve your manufacturing operations.
Suppose a method catches your curiosity or resonates with you in some way-investigate it further and determine whether to try it now or later. Many of these instruments can be used efficiently in isolation, making it much easier to get started. On the other hand, the gains will be increased with the use of additional resources, as they support and improve one another.
Most Helpful Lean Tools
Lean manufacturing utilizes various lean techniques to increase productivity and quality by making the most of each capital. Lean production is geared at discovering new ways of doing things: taking less work, less time, and less money. For one company, specific lean methods might be more useful than another.
Five S (5S)
5S is a five-step methodology intended to build and sustain an integrated visual workspace with a commitment to continual process change and performance.
This is a very realistic framework that aid to evaluate existing organizational space and remove what is not required.
- Sorting out – This move includes looking through all the resources and supplies in work to decide what is needed and what is not. Ask yourself: To find the worth of each item:
- What does this object have for purpose?
- Why is this in here?
- Whose level is it used?
- Who would use it?
Can’t find useful solutions to questions like this? Perhaps you need it not.
- Set in order – Once the needless chaos is gone, you can restructure the office to comply with the team’s priorities and urgent demands.
- Sweep – Develop a schedule to repair and disinfect the tools and equipment periodically
- Standardize – Transform the actions one time into patterns. If it’s an online guide or auditory updates, set aside time to help cultivate a structured atmosphere in which activities develop.
- Sustain – Achieve sustainability in the long run. If you’re a consultant or a novice developer, the new curriculum demands that everybody be on board. This is how it is so essential to log protocols to ensure they are easy to identify for process enhancement.
Kaizen
Kaizen is a lean tool that facilitates continuous improvement in quality, technology, procedures, efficiency, corporate culture, and safety when used correctly. Kaizen was developed in Japan during the Second World War and was used to help reconstruct after the war.
From top management to the cleaning crew, Kaizen leverages expertise and creativity from every employee. As a consequence, change ideas come from all aspects of the business: development, sourcing, marketing, logistics, finance, etc. In most cases, individual upgrades do not lead to substantial changes of their own; instead, a steady cycle of minor changes leads to meaningful increases in quality, protection, and performance, thus reducing waste.
Value Stream Map
A diagram of the value chain visualizes the steps involved in a product or service distribution. Through the value stream diagram, you can track critical details and see where the excess occurs, and if the required service was provided to the clients. These details can include TAKT time or the overall amount of time you may expend to meet consumer requirements.
Kanban
Kanban is a visual distribution method, where the delivery of parts to the production line is applied as desired, increasing performance. This lean method operates by ensuring employees have what they need, and when they need it.
Historically, workers used Kanban cards to show that they needed additional components, and new features were not issued until a card suggested a need for more features. More recently, physical Kanban cards are being replaced by a device that uses advanced software to electronically signal requests. More widely referred to as E-Kanban, the device will order new parts automatically using a set of barcodes that are scanned to indicate when new features are requested.
Problem Solving / PDCA / PDSA
The PDCA / PDSA loop is a graphical four-phase process for making improvements at the company. The process is cyclical so that you can replicate the PDCA / PDSA loop over and over again. Using this pattern at the source of a process improvement project is a good idea, especially for repetitive processes.
- Plan – Recognize a question or possibility while a roadmap for improvement is carried out. You would need to construct a theory of what the possible problems could be.
- Go-This is the process of research. Realistically, this would be a small-scale test where you can quickly calculate outcomes and grasp your theory better.
- Test-Determine whether it solves the problem.
- Act-Replicate it on a larger scale if the initial test was successful.
6. Developing Your Strategy
Every company is different so you need to practice to find the most suitable models and diagrams for your organization. However, you will find that even the most simplistic methods will dial on the potential of the company to eradicate duplication and concentrate on quality growth.
It may appear too big a job for a flowchart or diagram, but you’ll be shocked at the effect, these relatively simple methods have on Lean manufacturing practices in your implementation.
Learning these Lean tools and techniques requires training and some companies need certain individuals in the hierarchy to be certified in popular Quality Management Training programs. If companies want to stay competitive in this complex business landscape, then it is critical that individuals and enterprise teams are trained accordingly to meet market demands.
Some of the popular quality management training courses that individuals and enterprise teams can take up are:
