Improve Manufacturing

Delivering Six Sigma Manufacturing Excellence

Improve Manufacturing. Six Sigma performance is not necessary but, manufacturers that are running at less than 4.25 Sigma are leaving profits on the table. Increase Operational Excellence by operating like Toyota.
The Toyota Production System uses inventory strategically. For example, their Just-In-Time system receives parts every 2 hours. As a result strategically placed inventory helps their andon system absorb 800 pulls a year with minimal disruption.

Six Sigma Systems such as the Toyota Production System Benefits include:

  1. OPERATING AT GREATER THAN SIX SIGMA
  2. ANDON CONSTANT DEFECT ERADICATION (THANK YOU TAIICHI OHNO).
  3. MINIMIZE ASSEMBLY LINE WORKERS.
  4. “PULL” THROUGHOUT ASSEMBLY LINE (BUILD TO ORDER).
  5. INCREASE COMPETITIVENESS THROUGH OPERATIONAL EXCELLENCE.
  6. CERTAINLY, A WHOLE COMPANY QUEST FOR PERFECTION.
  7. DIRECTION TO EXCELLENCE BY GUIDING PRINCIPLES.
  8. CONSEQUENTLY, BUILD A CORPORATE CULTURE OF GREATNESS.
  9. INVENTORY IS USED STRATEGICALLY.
  10. CONSTANTLY STRESS AND MEASURE THE ASSEMBLY LINE.
  11. FINALLY, STRATEGIC SUPPLIERS DECREASE PRICE, YEAR OVER YEAR.

21 Step Detailed Program to Your Production System

The Toyota Production System, Improve Manufacturing:

Manufacturers exist in a competitive environment. Improve Manufacturing by using The Toyota Production System above all creates Operational Excellence. Though the following list seems simple, it is not. However, this is the path to Six Sigma Manufacturing Operational Excellence:

  1. Guidance to Six Sigma
  2. Identify Value Added
  3. Map the Value Stream
  4. Create Flow
  5. Establish Pull
  6. Above all, Seek Perfection

Cost of Quality vs. Sigma

That is to say, the Cost of Quality is onerous on those operating at lower Sigmas. As Philip B. Crosby tought in his book: “Quality is Free” that poor quality costs include:

  • increased warrenty costs,
  • rework costs,
  • customer satisfaction costs to reputation,
  • liability costs,
  • and so on.

For example, review this 9 minute video that highlights just the cost of failed products, ignoring all other costs for a ficticious company manufacturing a ficticious product:

A Mass vs. Lean Production Comparison

This is a comparison of Mass and Lean Prodution using a river ecosystem as an example. For example take a look at this 5 min video:

Build Your Lean Production System

Mass Production is full of waste (inventory) and departmantal based instead of Lean Production, the future of manufacturing. In Mass Production each department wins by performing fastest but that doesn’t mean your product production is faster. Speeding up the fastest performer instead of the slowest performer will not help overall performance. Lean Production measures performance of the whole Value Stream plus each process. Therefore if you want to move to Lean Production, watch this video:

Stress Your Assembly Line Like Toyota

Improving Assembly Line performance is key to growth and therefore you accomplish this by constantly stressing your Assembly Line. Likewise, you measure stress levels with andon calls:

Improve Manufacturing by Managing your Metrics

The Toyota Production System runs on Metrics. Subsequently I have listed the Metrics in this video. That is to say Metrics are based on measuring the value delivered with a Value Stream. As a result management requires the measurement of Metrics to monitor the production heartbeat and measure improvements:

Improve Manufacturing by Seeking Perfection

Toyota constantly seeks perfection through a powerful program named Kata. Kata delivers Continuous Improvement, Policy Propagation, and Realization. Above all it is a program, not a build on. Subsequently it requires understanding the Value Delivered with Value Streams. Kata delivers 11 Continuous Improvment ideas per person, per year. To clarify, all in a business benefiting direction. This 13 minute video takes you through the whole process. If you want to see this in detail visit my Lean Business website linked here. This video is just an overview:

In Conclusion

Once that you have Profound Knowledge of your processes and you are Managing by Value Stream you have taken the first step to Excellence. Next, use everyone in your company to march towards Perfection. After that, Start your journey to 6 Sigma operations.

The Toyota Production System, for example, allows you to:

  • Stress your Assembly Line,
  • Manage by Metrics, and
  • Above all Eradicate Defects with an andon system.

The Toyota Production System is powerful, moreover, use it to Power your Production System.

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