Lean Six Sigma – Manufacturing

In the current business environment the greatest challenge is to attain and sustain global competitiveness in domestic and global market along with profitable growth of company. Due to rising cost of raw materials, energy, labour and high operating expenses overall production cost is continuously going up and profit margins shrinking.

The current priority for the company is to streamline its production system right from the receipt of order to production and delivery of products/services to customers in shortest leadtime without any delay and waste. This can be made possible by attaining operational excellence through deployment of Lean Six Sigma Manufacturing in all processes including; design/development, procurement, production, delivery and supporting services.

Lean Six Sigma Manufacturing

Lean Six Sigma Manufacturing is the most efficient management system to design, produce and deliver world-class quality products, just-in-time at competitive price to customers. The objective of Lean Six Sigma is to develop the value streams capable to design, produce and deliver the products and services as per customer’s specification based on JIT system.

To ensure the timely delivery of products/services it is essential that every process, right from order to delivery is leveled in such a way that process cycle time is matching with the demand rate (takt time). This can be made possible by detection and elimination of waste through deployment of Lean Six Sigma manufacturing techniques in entire operations of company.

Ultimate outcome of Lean Six Sigma implementation is measured in terms of; reduction of lead time, reduction of inventory and other waste resulting to lower cost.

Benefits Of Lean Six Sigma Manufacturing

Implementation of Lean Six Sigma Manufacturing will provide following benefits:

  1. Improve product quality
  2. Reduce production cost
  3. Reduce order to delivery lead time
  4. Reduce inventory carrying cost
  5. Improve the workplace condition
  6. Improve utilization of machines, materials and human resources
  7. Improve equipment availability
  8. Introduce continuous improvement culture
  9. Improve competence of employees
  10. Improve profitability of the company

Lean Six Sigma Implementation Strategy

Lean Six Sigma implementation is based on belief that the people who are touching the process are true experts therefore all improvements can be practically and effectively done by developing “Lean Six Sigma Behavior” of people through a series of knowledge and skill development training programs, counseling and mentoring by experienced Lean Six Sigma Consultant.

For successful Lean Six Sigma implementation the four key areas need to be aligned and improved in line with Lean Six Sigma principles are; people, processes, workplace and management system. Brief description of consulting activities and deliverable in the four areas is presented below:

Improvement Areas Activities Deliverables
1. People Lean Six Sigma Awareness Training Lean Six Sigma Foundation & Implementation Training Enhanced Knowledge & Skills of people to identify process problems and solve it by applying Lean Six Sigma tools
2. Processes Base line performance Audit, Constraint Diagnosis & Problem Solving, Six Sigma tools Improved Quality, Reduced Cost & Improved On-Time Delivery, Reduced Waste
3. Workplace Five S & Visual Management Systematic & well organized workplace
4.Lean Six Sigma Management System Introduce Lean Six Sigma Management System Continuous improvement, effective planning, monitoring & control