Bottlenecks in a manufacturing process can significantly reduce production levels and cause lost opportunity. Identifying the root cause of a bottleneck requires a rigorous investigation using tools like value stream mapping, 5 whys analysis, and design of experiments. For a home furnishings manufacturer, TriVista used these techniques to determine that dust particles in the paint from inadequate paint room conditions were causing defects. This was slowing down the entire production process. TriVista developed solutions like improving the paint room layout and implementing process controls to boost production by up to 40%. To effectively manage bottlenecks, companies need to take a comprehensive, data-driven approach to uncover and address the true underlying causes.
Yellow belt process improvement training and certification moduleVishy Chandra
Free Yellow Belt Training in Process Improvement for all those who want to get started with a formalized approach to process improvement.
Module contains Kaizen, PDCA, 8D, TOC, Lean and Six Sigma. By the end of the module, the trainee will be able to identify a project opportunity in their organization and that will be eligible for free certification.
Basic overview six sigma, Six Sigma is a production philosophy that uses data, processes, and tools to nearly eliminate defects and bring performance close to perfection. Specifically, achieving Six Sigma means that no more than 3.4 defects occur per one million “opportunities” to create an acceptable output
Six Sigma Principles And Concepts PowerPoint Presentation SlidesSlideTeam
Are you looking to take up your six sigma methodology PowerPoint show to next level? Just check out our presentation deck to thoroughly explain your six sigma approach or simply what is six sigma? By utilizing this PPT example you can motivate your employees to go for team formation so as to improve overall performance of your business processes. Additionally, with help of our PPT slideshow you can easily identify various defects and suggest measures to timely remove and maintain quality management. There is more that you can address with this PPT model like various levels of six sigma, design for six sigma, lean six sigma process improvement tools and techniques. Well bearing all this in mind, we have conceptualized creative presentation layouts like six sigma roadmap, six sigma process, the DAMIC process, voice of customer are just a few to name here. In nutshell, by downloading our six sigma principles and concepts complete PowerPoint slide deck you not only save your time, but also get best readymade PPT sample. Get your audience singing from the same sheet. Our Six Sigma Principles And Concepts Complete Powerpoint Deck With Slides can create harmony
----- a french version is available upon request ----- This is a short - and I hope Zen ! -presentation (15 mn should be enough) aiming to make Executives, Board of directors, employees aware of what Lean Six Sigma is and the benefit they could have implementing it.
I've been asked to put together a basic (and therefore relatively quick) introduction to Lean Six Sigma & DMAIC. While it’s not yet finished, I thought I would put it out there for people to comment on. Since the presentation is supposed to be training material there’s more text on the slides than I would prefer, but there are a few exercises and games to get the trainees involved.
I've put the PowerPoint version on my blog:
http://alesandrab.wordpress.com/2013/06/07/introduction-to-lean-six-sigma-dmaic/
Yellow belt process improvement training and certification moduleVishy Chandra
Free Yellow Belt Training in Process Improvement for all those who want to get started with a formalized approach to process improvement.
Module contains Kaizen, PDCA, 8D, TOC, Lean and Six Sigma. By the end of the module, the trainee will be able to identify a project opportunity in their organization and that will be eligible for free certification.
Basic overview six sigma, Six Sigma is a production philosophy that uses data, processes, and tools to nearly eliminate defects and bring performance close to perfection. Specifically, achieving Six Sigma means that no more than 3.4 defects occur per one million “opportunities” to create an acceptable output
Six Sigma Principles And Concepts PowerPoint Presentation SlidesSlideTeam
Are you looking to take up your six sigma methodology PowerPoint show to next level? Just check out our presentation deck to thoroughly explain your six sigma approach or simply what is six sigma? By utilizing this PPT example you can motivate your employees to go for team formation so as to improve overall performance of your business processes. Additionally, with help of our PPT slideshow you can easily identify various defects and suggest measures to timely remove and maintain quality management. There is more that you can address with this PPT model like various levels of six sigma, design for six sigma, lean six sigma process improvement tools and techniques. Well bearing all this in mind, we have conceptualized creative presentation layouts like six sigma roadmap, six sigma process, the DAMIC process, voice of customer are just a few to name here. In nutshell, by downloading our six sigma principles and concepts complete PowerPoint slide deck you not only save your time, but also get best readymade PPT sample. Get your audience singing from the same sheet. Our Six Sigma Principles And Concepts Complete Powerpoint Deck With Slides can create harmony
----- a french version is available upon request ----- This is a short - and I hope Zen ! -presentation (15 mn should be enough) aiming to make Executives, Board of directors, employees aware of what Lean Six Sigma is and the benefit they could have implementing it.
I've been asked to put together a basic (and therefore relatively quick) introduction to Lean Six Sigma & DMAIC. While it’s not yet finished, I thought I would put it out there for people to comment on. Since the presentation is supposed to be training material there’s more text on the slides than I would prefer, but there are a few exercises and games to get the trainees involved.
I've put the PowerPoint version on my blog:
http://alesandrab.wordpress.com/2013/06/07/introduction-to-lean-six-sigma-dmaic/
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
six sigma is a vibrant topic in quality management
i had made this one in my total quality management subject in mba.
u can take this but leave a comment if u like it
This presentation answers few points nd simple questions:
What is an A3 Report?
How to create one?
What applications it is used for - not just Solving Problems.
What makes a "Good" A3 Report.
Six Sigma Methodologies and its Application in Manufacturing FirmsDr. Amarjeet Singh
Six Sigma is a methodology for process improvement as well as a statistical concept that looks for to determine the variation intrinsic in any process. Six Sigma represents process, that is having 3.4 defects per million opportunities. i.e. 99.99966 % of the products from a Six Sigma process are perfect. Firms can impact their sigma level by combining main principles from the Six Sigma methodology into leadership styles, process management, and improvement activities. Main principle of the technique is a focus on the customer. There are many challenges in the implementation of Six Sigma. A well-run manufacturing team can make the entire firm more successful through cost-saving measures, increased quality and a larger inventory of products that the company can market. The Six Sigma objective is to make sure the process has minimum defects(3.4 defects per million chances). Every aspect of the process must be carefully planned and documented in detail in order for manufacturing to go efficiently. The main aspect of Six Sigma for enhancement in the manufacturing industry is to maximize the financial returns.
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
six sigma is a vibrant topic in quality management
i had made this one in my total quality management subject in mba.
u can take this but leave a comment if u like it
This presentation answers few points nd simple questions:
What is an A3 Report?
How to create one?
What applications it is used for - not just Solving Problems.
What makes a "Good" A3 Report.
Six Sigma Methodologies and its Application in Manufacturing FirmsDr. Amarjeet Singh
Six Sigma is a methodology for process improvement as well as a statistical concept that looks for to determine the variation intrinsic in any process. Six Sigma represents process, that is having 3.4 defects per million opportunities. i.e. 99.99966 % of the products from a Six Sigma process are perfect. Firms can impact their sigma level by combining main principles from the Six Sigma methodology into leadership styles, process management, and improvement activities. Main principle of the technique is a focus on the customer. There are many challenges in the implementation of Six Sigma. A well-run manufacturing team can make the entire firm more successful through cost-saving measures, increased quality and a larger inventory of products that the company can market. The Six Sigma objective is to make sure the process has minimum defects(3.4 defects per million chances). Every aspect of the process must be carefully planned and documented in detail in order for manufacturing to go efficiently. The main aspect of Six Sigma for enhancement in the manufacturing industry is to maximize the financial returns.
The International Journal of Engineering and Science (The IJES)theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The purpose of the paper is to improvise the six sigma process applied on the Wine making process using the TRIZ principles for the following problem.
The problem faced by the industry is that “Dry wines contain substances beneficial to human health; however, they cannot be given to children. The alcohol can be evaporated from the wine by boiling, but the high temperatures destroy the beneficial substances in the wine.”
Our approach to improve the process would be applying the 40 principles of TRIZ to the wine making process. The solution for the problem was found in the principles of physics using which used the concepts of pressure which are entirely outside the boundaries of wine making process.
Blytheco’s Business Process Optimization is an effective tool for keeping your company’s technology in tune with your goals. The Business Process Optimization service allows us to understand your business, so that we may help you do your job better, faster, easier, and more effectively.
We can help you give your business system a “tune-up” and help you evolve as your goals and environment adapt to changing business realities by identifying inefficiencies in current processes and offering cost-effective options to maximize your technology investment.
Lecture 13Application of Six Sigmain Service operati.docxsmile790243
Lecture 13
Application of
Six Sigma
in Service operations
Opportunity of Six Sigma
in Service organizationType of service organizations: Healthcare, banking, government, marketing, sales, accounting, production control, engineering, R&D etc.Service has a tremendous opportunity for Six Sigma projects.Generally, the service organizations have 30-80% waste in the processes & many activities add no value to the customers.
Example 1Type of the organization:
Software companySix Sigma project:
Improve customer order fulfillment process Six Sigma tools used
1) Statistical process control (SPC)
2) Pareto charting
3) Normal probability plotting
4) Design of Experiments (DOE)
Example 2Type of the organization:
Pharmaceutical testing companySix Sigma project:
Improve iterations of paperworkSix Sigma tools used
1) Statistical process control (SPC)
2) Pareto charting
Example 3Type of the organization:
Aerospace service companySix Sigma project:
Reduce warranty return rate after servicing products Six Sigma tools used
1) Statistical process control (SPC)
2) Pareto charting
Example 4Type of the organization:
City governmentSix Sigma project:
Evaluate the differences between city home inspectorsSix Sigma tools used
1) Sampling techniques
2) Statistical process control (SPC)
3) Pareto charting
Example 5Type of the organization:
School districtSix Sigma project:
Improve attendance in the school district Six Sigma tools used
Design of Experiments (DOE)
Example of Six Sigma project to improve
on-Time delivery
Data for late deliveries (61%)
SPC chart for current late deliveries
Pareto chart of late deliveries
Pareto chart of deliveries after improvement
SPC chart for new late deliveries
Example of Six Sigma project to increase
website traffic
Data on website “hit-rate”
SPC chart for website hit rates
Cause-and-effect matrix of website traffic
Steps to reduce the size of DOE
Review the list of factors from the cause-and-effect matrix.
Pare it down to factors that would yield insight into website traffic
Conduct a meeting of peers from all affected areas to consider expansion or deletion of selected factors (variables) for the experiments.
Group the input variables (factors) into two levels to represent the extreme of each setting.
Factors (variables) of website hit rate test
DOE test matrix
Results of implementing Six Sigma
Eight pages were created
Each page representing one of the trials listed in the DOE table
Hit rates were then collected on a weekly basis to determine which combination of factors produced the most traffic
Based on the results of the experiment, the team could determine which factors to focus on in order to increase traffic on the company website
Additional application of Six Sigma
A major appliance repair company used Six Sigma to improve its ability to return items to customers when promised.
A pharmaceutical company used Six Sigma t ...
How to Reach Peak Performance With the Product Management Organizational Heal...Aggregage
The degree of maturity of your product management organization can directly drive your ability to satisfy customers and become more profitable. Our Product Management Organizational Health Checklist and on-demand webinar can help.
Similar to TriVista - BlogPost - Production Bottlenecks (20)
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TriVista - BlogPost - Production Bottlenecks
1. Are bottlenecks keeping your
operation from fulfilling its potential?
BY MIKE CATALANO | TRIVISTA ASSOCIATE
B
ottlenecks—the steps in
a process that govern
the speed of the entire
operation—are a common headache
in the manufacturing world. Unlike
the bottlenecks we experience in
our daily lives, such as a broken-
down car on the freeway making us
late for work, production bottlenecks
are not simple annoyances or
inconveniences. On the contrary, in
a business they can translate into
significant opportunity loss if left
untreated. Yet, while it’s often easy
to identify a bottleneck on the shop
floor, figuring out how to manage it is
a much more complex undertaking.
The root cause of a bottleneck is
often buried deep inside a process
and only becomes apparent
through rigorous investigation and
experimentation.
Consider the case of a high-end
home furnishings manufacturer.
The company was failing to meet
its production targets for one of its
most popular items because the
manufacturing process of a key
component was continually falling
behind. Prior to final assembly,
this component required significant
amounts of sanding, painting,
and buffing—a process that rarely
went as smoothly as the company
expected. In fact, the department
responsible for this component
regularly found itself having to
rework, and sometimes even scrap
the product due to a wide range
of defects. Doing so not only
slowed down the entire production
process for the end product, but
also cost the company hundreds of
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www.linkedin.com/company/trivista
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2. thousands of dollars in wasted labor
and materials.
It was clear the paint department’s
inability to consistently produce
components that met the
company’s quality standards was
the bottleneck. What wasn’t so
clear was the root cause of that
inconsistency. Why were defects
able to find their way onto the
finished component despite
workers’ best efforts to avoid them?
The company needed help and
asked TriVista to find a solution.
Our team first used Value Stream
Maps and Pareto Analysis (Figure
1) to assess the existing process
to track the number and types of
defects produced over a four week
timeframe. This in-depth analysis
revealed that dust particles in the
paint was the single-biggest cause
of rework. Knowing this, we then
had to determine the source of
the dust. Although a large range
of variables in the paint process
could have been causing the
contamination, by using Design
of Experiments (DOE) and other
advanced statistical methods, we
found that the facility infrastructure
and lack of discipline required to
control paint room conditions was
the primary contributor to the
bottleneck. Our team developed
a relatively inexpensive solution: a
more efficient layout and process
for the existing paint room and
production facility. We also designed
and implemented a future state
facility change to ensure continued
success of the new process.
By locating and managing the
true cause of the bottleneck,
the company was able to boost
production by as much as 40
percent—allowing them to keep
pace with demand and increase
revenue.
The home furnishings company’s
experience is a perfect example
of why a rigorous and disciplined
approach is needed to resolve
(888) 694-1484 | WWW.TRIVISTA.COM | INFO@TRIVISTA.COM
FIGURE 1
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
$-
$100,000
$200,000
$300,000
$400,000
$500,000
$600,000
$700,000
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
SALES PARETO
3. production bottlenecks. Such an
approach typically incorporates the
DMAIC Process (Figure 2):
Define:
As mentioned earlier, a company
generally knows where the
bottleneck is: It’s the slowest
activity delaying the rest of the
process. However, pinpointing the
reason why that particular activity
is slow is crucial, and requires more
than a casual look. Two powerful
tools are especially useful in
helping a company identify areas
that merit deeper investigation.
One tool is a Value Stream Map,
which illustrates the entire activity
or process, including cycle time,
current steps, delays, information
flows, and defects. Another is a
Spaghetti Diagram (Figure 3), which
helps pinpoint wasted movements
that are adding unnecessary time
to a process.
Measure:
To be able to improve a process,
it is essential that a company
understands where it’s starting
from. Therefore, it must collect a
wide range of process performance
data to establish a current
baseline. Ultimately, this baseline
will be compared to performance
metrics gathered after the project
is complete in order to objectively
determine whether significant
improvement has been made.
Analyze:
Getting beneath the surface and
uncovering what’s really going
on generally requires next-level
assessment tools such as the “5
Why” Analysis and a Fishbone
Diagram, which help uncover cause-
and-effect relationships. In some
instances, use of these tools may
reveal that a bottleneck has multiple
causes, in which case a company
must then determine how it wants
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STAGING AREA
NEW PRODUCT
STAGING AREA
NEW PRODUCT
STAGING AREA
PRODUCTION AREA
PACKING AREA
SCALE
OFFICE
SCRAP
STAGING
AREA
INVENTORY
INVENTORY
UNLOADING ZONE
INVENTORY
Current State flow
Future State flow
SPAGHETTI DIAGRAM
FIGURE 3
FIGURE 2
4. to address them. A Pareto Analysis
is helpful here, as it enables a
company to prioritize the necessary
changes based on which will be
most successful in eliminating or
reducing the bottleneck.
Improve:
Once a company knows which root
cause to attack, it can then design
and implement a solution. Typically,
a solution will involve either Lean
Management, Six Sigma Principles,
or many times a combination of both.
A lean solution is one that primarily
targets reducing waste—especially
excess steps or movements that
can slow a process down. Six Sigma,
on the other hand, focuses on
reducing variation through methods
such as statistical modeling and
experimentation (as was the case
with the furnishings manufacturer).
In either case, a solution may entail
new processes, new systems, new
skills, or sometimes even a change
in company culture.
Control:
To ensure the new process
maintains optimal performance,
a company must monitor and
control it. Methods such as Visual
Management and Statistical Process
Control help a company keep
tabs on the operation by spotting
potential signs of problems, such
as a drop in quality or output, thus
enabling them to respond quickly.
It’s worth repeating that the
purpose of this approach is finding
the true cause of a bottleneck, not
simply addressing the symptom
as many companies are apt to do.
For instance, the home furnishings
company knew its paint and finish
process was slower than desired
because of defects in the finish,
but a common sentiment in the
organization was that the defects
would subside if painters were
better trained or had better paint
guns. Without taking a more
comprehensive look at its operation,
the company may have wasted
more time and money on training
programs and new equipment
which would have yielded the same
results – a high amount of rework
and scrapped components.
Just because a company learns to
manage and improve one bottleneck,
doesn’t mean the job is done. There
will always be a bottleneck, a slowest
activity, or process that prevents
an operation from running at full
potential. That’s why maintaining
a continuous improvement mindset
is critical to managing bottlenecks
as production processes develop
and change to meet customer
requirements. The ultimate goal
is to manage bottlenecks as much
as possible to ensure production
can continue to efficiently and
effectively satisfy demand.
For more information on Production
Bottlenecks, please contact us at
info@trivista.com or call 949-218-4830.
(888) 694-1484 | WWW.TRIVISTA.COM | INFO@TRIVISTA.COM
ABOUT THE AUTHOR
Mike Catalano brings TriVista clients a dynamic range of Mechanical Engineering
skills paired with deep Lean Six Sigma knowledge and experience to develop and
implement continuous improvement projects. Since joining TriVista in 2011, Mike has
led and supported over 25 engagements in the US, Canada, and Mexico helping
businesses eliminate waste, improve quality, and increase productivity through
operational excellence. As an Associate, Mike excels in statistically analyzing
data, diagnosing problems, developing solutions, and not only implementing those
solutions but training onsite staff in maintaining improvements.
To learn more about our services, visit www.trivista.com, call 949-218-4830, or email
info@trivista.com.
MIKE CATALANO
ASSOCIATE