2. • Lean manufacturing is a business model and collection of
tactical methods that emphasize eliminating non-value added
activities (waste) while delivering quality products on time at
least cost with greater efficiency. In the U.S.,
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3. lean implementation
• is rapidly expanding throughout diverse
manufacturing and service sectors such as
aerospace, automotive, electronics, furniture
production, and health care as a core business
strategy to create a competitive advantage
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4. Lean Thinking and Methods
• Six Sigma consists of a set of statistical methods
for systemically analyzing processes to reduce
process variation, which are sometimes used to
support and guide organizational continual
improvement activities. Six Sigma's toolbox of
statistical process control and analytical
techniques are being used by some companies to
assess process quality and waste areas to which
other lean methods can be applied as solutions.
Six Sigma is also being used to further drive
productivity and quality improvements in lean
operations.
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5. Method and Implementation
Approach
• A sequence of steps called the
Six Sigma DMAIC (Define,
Measure, Analyze, Improve,
and Control) is typically used
to guide implementation of Six
Sigma statistical tools and to
identify process wastes and
weaknesses. Six Sigma DMAIC
phases include:
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6. • Define. This phase focuses on defining the project
improvement activity goals and identifying the issues
that need to be addressed to achieve a higher sigma
level.
• Measure. In this phase, the aim is to gather
information about the targeted process. Metrics are
established and used to obtain baseline data on
process performance and to help identify problem
areas.
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7. • Analyze. This phase is concerned with
identifying the root cause(s) of quality
problems, and confirming those causes using
appropriate statistical tools.
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8. • Improve. Here, implementation of creative
solutions - ways to do things better, cheaper,
and/or faster - that address the problems
identified during the analysis phase takes
place. Often, other lean methods such as
cellular manufacturing, 5S, mistake-proofing,
and total productive maintenance are
identified as potential solutions. Statistical
methods are again used to assess
improvement.
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9. • Control. This phase involves
institutionalization of the improved system by
modifying policies, procedures, and other
management systems. Process performance
results are again periodically monitored to
ensure productivity improvements are
sustained.
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