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Manufacturing Systems Analysis

Manufacturing Systems Analysis. 6 SiGMa vs. Kaizen/Lean. Comparative Analysis. 6 s. Improvement Methodologies Similar in Structure Improvements measured against established process Team oriented Similar improvement tools Measure effectiveness of improvements

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Manufacturing Systems Analysis

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  1. Manufacturing Systems Analysis 6 SiGMa vs. Kaizen/Lean

  2. Comparative Analysis 6s • Improvement Methodologies • Similar in Structure • Improvements measured against established process • Team oriented • Similar improvement tools • Measure effectiveness of improvements • Maintain new performance level • Standardize & Proceduralize • Results • More Efficient Processes • Comparison • Both are Effective Improvement Mechanisms • CPI/6s best applied to large complex problems • Kaizen/Lean best applied to achieve incremental changes and eliminate wastes. Kaizen/Lean Measure - Data Collection - Determine Process Potential / Goals Evaluate - Root Cause / Vital Few - Statistical Analysis Improve & Verify - Implement Improvement - Validate Improvement Standardize - Standardize / Leverage - SPC - Update Procedures Evaluate - Baseline Process Performance - Establish Target Decide -Compare solutions - Choose Act -Communicate - Implement improvement - Control Measure - Validate improvement - Standardize - Update Procedures Focus - Reduce Process Variation - Identify Critical Cause and Focus Resources for Maximum Impact Focus - Eliminate Waste 5S - Seek Incremental Process Changes Summary - Common Sense Approach based on Observation - Applicable to all types of processes - Defined improvement strategy - Typical Projects 1 week Summary - Technical Approach based on Statistical Analysis - Requires Significant Data Collection - Best applied to Manufacturing Processes - Typical Projects 1-3 Months

  3. What is 5S ? • An essential step required for Waste Elimination • An integral step in Kaizen • A required element to implementing Lean Manufacturing. Systematic Organization “Seiri” Orderliness “Seiton” Cleanliness “Seiso” Cleanup “Seiketsu” Cleanup “Seiketsu” Standardization/Perseverance “Shitsuke”

  4. Elimination of Waste

  5. Comparing Approaches • Kaizen • Philosophical Approach • Common Sense Approach • (Qualitative) • Data Driven - Observation • Operational Focus • Waste Elimination 5S • Incremental Change • Smaller/Shorter Projects • 6 Sigma • Disciplined Methodology • Technical Approach • (Quantitative) • Data Driven - Statistical • Customer Focus • Reduce Variation • Focus on Large Impact • Larger/Longer Projects Complimentary Tools Driving Continuous Improvement

  6. References • Qualitytoolbox.com

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