Everything we do is not beyond error or defects but there’s always room for everything to make it more effective, error-free, optimized, and staff. For a very long time, there’s been a debate about Lean or Six Sigma and choosing the best fit process between these two to eliminate waste and error in business houses. Alright, both these two are potentially important and effective in reducing waste and ensuring more customer value in business. So, not diving into the debate, let’s look into two of those in a short possible way.
In 1940, the giant car company, Toyota came up with the ideology of Lean in their production system to cut down their waste. Here waste means the steps or processes in the production system or supply chain process that don’t add any value to the output. What the Lean process focuses on is to ensure customer value and satisfaction through removing wasteful steps and emphasizing value-added steps. Improving the production and delivery time through reducing the process cycle time, eliminating the percentage of defects, and moreover optimizing the whole cyclic process and ensuring continuous improvement are the major key steps of Lean.
The methodology helps in solving raised problems and errors and ensures product quality. This data-driven continuous process emphasizes reducing errors and defects to ensure customer value or satisfaction from the customer point of view. The process Six Sigma includes a framework named, DMAIC, which consists of 05 steps through which Six Sigma acts as a problem or error detective tool. The steps of the framework are:
- Define: In this stage of the framework, we are to define or outline the objective of our venture and even the problem or error we are being through. It is said that knowing the problem is a half solution. So the most and first steps are to define the issue clearly which we are into.
- Measure: To make sure the analysis we will be doing, is based on the current performance of the production, services, and process we need to measure the current performance percentage. Without having an accurately measured indication of our current production or service, we might be misled, analyzing the issue based on a hypothetical value.
- Analyze: After we get the data from the measuring phase, we need to analyze the production, process, service, and staff using that obtained data to figure out the reason for which the issue we are with. The analysis phase aids us in pointing out the root cause of the arisen problem which definitely brings us to a better and specific solution.
- Improve: Having the analysis report in hand the next step is to design the polish the taken decision against the problem or defect that we are working on. Once the final root cause is tracked down, we must come up with a solution along with some alternatives to that issue, and these all steps are taken down in this phase of the framework.
- Control: The last phase of the framework, control includes ensuring the implementation of changes and newly undertaken solutions to our service, production, or process and even put the whole system under control. Holding the expected output is the sole purpose of this stage through implementing the solutions in a sustainable manner.
Lean Six Sigma is an integrated managerial approach to ensure sustainable continuous improvement through eliminating wastes and errors. As we know, there has always been a debate on choosing any best of these two defect elimination processes but after we came across with the combination of these both, we got definitely far better output than we used to get ever before. In this dynamic era of industrialization, we will be falling behind if we are not updated and get adapted to these game-changing tools and techniques. Success obviously lies in continuous and sustainable qualitative improvement in everything we do in life.
YSSE Admin & HR Department.