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Six Sigma Quality Process Improvement
- 1. Over-Processing Over Production Defects Matching Skills to Personnel Transportatio n Inventory Motion Waiting SIX SIGMA QUALITY
- 2. TRANSPORTATION With the expansion of businesses, transportation has found new avenues and developed new platforms to be competitive in the market place. Company Owned vehicles, Brokered Accounts, 3PL, 4PL, Managed Services; the transportation platforms has a wide range of options, advantages and disadvantages. Knowing these options is half the battle. The second half of the battle is keeping up with the changes.
- 3. INVENTORY Inventory, Raw Materials or Finished Goods, you must have the right products at the right time. Out of Stocks can cause: Production Slow Down or Shut Down Missed Sales Customers finding new supplier of products INVENTORY section would include • Receiving – verify the inbound product – OSD • Locations – consider High Pick Slots for high volume • Rotation – make sure the oldest product is pulled first (FIFO) • Transfer – when product is moved, ensure WMS is updated • Shipping – verify the outbound product • Returns – verify product stability and slot properly
- 4. MOTION What is the shortest distance between 2 points? Straight Line. When developing a production line, warehouse, in-bound and out-bound distribution, the straight line principal can be highly effective and reduce: • Misplacement • Traffic Mishaps • Movement energy
- 5. WAITING We are a society to hurry up and wait. Six Sigma Quality prepares us to develop the entire process with a flow. Step 1 is complete on to Step 2. The Waiting methodology works closely with Motion methodology. The goal is for the motion to be limited while going to the next step. Picture a car assembly line. The entire line will be held up if a part is missing somewhere in the assembly line.
- 6. OVER PROCESSING Make the processes as simple as possible. Do not complicate the process. If it can be accomplished in 4 steps, do not use 5 steps. Be precise in defining the process.
- 7. OVER PRODUCTION Over Production has many different negative aspects: • Storage • Warehouse Loss • Marketing & Sales must change their focus to sell product at a reduced price.
- 8. DEFECTS Defects can be defined as Scrap and Rework. • With a Defect-Scrap, the company will loose the value of materials, labor, overhead, trash removal, and more. • With Defect-Rework, the Finished Product will be sold, however, additional time (which has a cost) will be required to complete. Defect-Rework slows down the production line into the Waiting section. Time is money. Going through Rework increases cost (which will be lost dollars) without the ability to sell at a higher price.
- 9. MATCHING SKILLS TO PERSONNEL Matching the correct skill set to your personnel is important. If you are good at something, you should perform that task. A great salesperson should not take a management position. Concentrate in making your skill set better.
- 10. Define Measure AnalyzeDesign Verify FUNDAMENTALS OF DMADV This methodology is used to develop processes.
- 11. DEFINE MEASURE ANALYZE DESIGN VERIFY What is the project? What are the goals and deliverables? Measure the areas that are critical to quality? Determine the critical points and how often they occur. Let this be your guide in developing the analysis. Here you can define where everything will be placed; how it should flow; challenges in the process; and how they should be addressed. The verification allows for the process to be validated and improved, if needed.