First briefly describe the Lean tool you chose for this week’s Discussion (the T
ID: 346900 • Letter: F
Question
First briefly describe the Lean tool you chose for this week’s Discussion (the Tool used was DMAIC). Then, explain how the tool you chose can be applied to the problems highlighted in your chosen scenario. Finally, provide at least two examples to illustrate your point.
Scenario: Skilled trades at a leading automotive components company are the only ones who can replace a screen with an operating machine, even though it is a simple process. One thought is that some Operators could be trained to do this function, thereby freeing up skilled trades to do critical work. Which Lean tools can help achieve this outcome?
400 words total [ORIGINAL QUALITY WORK required]
Explanation / Answer
Answer:
Lean method (includes Six sigma): Lean processes are defined as the processes which are optimized and efficient and can deliver the desired output with a higher controlled manner i.e. it is controlled in plus /minus six sigma. Thus this processes results in very low defect. A six sigma process results in 3.4 ppm levels. Lean processes are the processes which are equipped with lean or six sigma tools, which helps the process to reduce their assignable causes and convert it into optimized and efficient process for the organization. All the lean tools and six sigma tools are the tools of lean/six sigma process and these are helpful in reducing the process assignable variations.
Six Sigma Methodology – It is the statistical based methodology which is used in the organization for better quality improvement by improving the products and processes of the organization. So six sigma is a methodology used at the organization level to improve the processes and product of the organizations in such a way that the quality defect levels are at 3.4 ppm. This is the biggest achievement in quality. The six sigma processes and products result in 3.4 ppm levels. Hence this is the methodology which will be instrumental in achieving the lowest ppm levels in the organization.
There are two ways the six sigma methodology can be applied at the organization level, as below
Process Improvements (DMAIC ) – This methodology is mainly focus on improving the processes of the organization. This sets the process in such a way that they will results with 3.4 ppm levels. This approach follows the structural methodology for process improvements. It follows the DMAIC cycle. The DMAIC cycle calls for define, Measure, Analyze, Improve and Control phases. Each phase has the adequate tools to apply at the process level and finally the process is improved to the desired level. The improved process is controlled and monitored for sustainability of the results.
Application of DMAIC tool : The DMAIC tool stands for Define, Measure, Analyze, Improve and Control. Sp we can apply these DMAIC tool in five steps starting define of the problem, then organize the measures for the project, so that it is clear that the stated objective is measured correctly and it is the problem and not the measurement issue. Then organize suitable data for statistical analysis, which is the stringiness of this tool. Then identify the action plan based on analysis to improve the process. Then last step is to introduce control plan to ensure the changes sustain for longer time.
Example :
Project 1 : Improve the productivity of the process from Xlevels to Y lever without increasing resources.
Project 2: Reduce the defect levels of process from X ppm to Y ppm without affecting productivity and lead time.
Benefits of DMAIC Process:
Shortfalls of DMAIC :
Scenario: Skilled trades at a leading automotive components company are the only ones who can replace a screen with an operating machine, even though it is a simple process. One thought is that some Operators could be trained to do this function, thereby freeing up skilled trades to do critical work.
The lean tool is train the trainer.
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