All entries for February 2009

February 28, 2009

DMAIC and Automation

Autonomation is basically that if there is any problem in the machine that is causing defects, the the entire production line comes to a hault till the problem is fixed. It is used in Toyota Production System and Lean Manufacturing.  It may be described as "intelligent automation" or "automation with a human touch." There is supervision required in this process. At Toyota this usually means that if an abnormal situation arises the machine stops and the worker will stop the production line. Autonomation prevents the production of defective products, eliminates overproduction and focuses attention on understanding the problem and ensuring that it never recurs. It is a quality control process that applies the following four principles:

  1. Detect the abnormality.
  2. Stop.
  3. Fix or correct the immediate condition.
  4. Investigate the root cause and install a countermeasure.

This is very similar to the DMAIC process according to me. This process involes define, measure, analyise, improve and control.

DMAIC can be applied to Autonomation process when there is a problem!!! this is how lean can be mixed with six sigma can be applied together

Just in time system and Six Sigma

In six sigma we know that customer focus is really important. In lean manufacturing I came across a process which can really eliminate high storing cost. The process is called just in time (JIT). There has to be "quick communication" in this process. This is required as old stock gets over one can quickly call for new one, eliminating the need of storing or buy a warehouse. Dell is one of the companies that have highly benefited from this system and achieved a competitive edge. This technique is also used by Toyota. It was first started at Ford.

This system is not mentioned in six sigma but can be intergrated in the system in the "Improve" stage of DMAIC process to reduce cost. This could be an option.

This system may not work in all industries but for the one where it works, it can bring great sot benefit.

Though six sigma and lean manufacturing have some different policies, many people are bringing them together with lean six sigma. This shows that both can be combined.

February 19, 2009

Mistake Proofing—PokaYoka

One of the things I remember being mentioned in our PIUSS module breifly was the work Poka Yoka. Which means to remove any mistake in the process which exist. One can do so in may ways such as training the labours or standardisation, or negative consequence for the labour for doing something wrong, or making the process so good that even if the labourer is day dreaming it would not affect his or her work.

Its a very interesting concept. I like it as much as my new developed affinity towards spc. Right now I am having a special cause variation in my working itself. As u might have read in my earlier blog, I am not feeling well which has been affecting my productivity. I am on medication so hopefully should feel better soon!!

I think the plane building competition in which both teams competing were in control has so far been the best experience I had in wmg. Actually doing the excercise yourself gives you great understanding of the process and the formulas we used to calculate the mean and standard deviation and so on. I also loved the case study which Professor Knowles had worked on in the candy factory which faced problems of the air bubbles.

WMG—–PLUS and NEGTIVE points!!—Reflective thinking

I am not sure if my class mates would agree if I have changed over the last 6 months. Well I would not lie. Warwick has changed me for the better. I see my self more patient and confident a person. Initially when I cam to warwick I did not like it and I hated the wmg style to teaching. The 9 to 6 classes and sitting at home and working on your pma. I really felt it made one anti social.......but I realised I have become more pateint as a person. Developing certain skills here and dealing with different issues has made me more confident a person.....

Well the class journey is almost coming to an end. I am definately going to miss our class a lot!! I love my class mates but in a way I am happy to be done with the 9 to 6 classes!! Its very tedious and by the end of it one is so saturated and barely can pay attention to what the professor has to say!!

Six Sigma—and also thank team members

Its is impotant to see that Six sigma is so difficult to achieve. 3.4 million defects per million?? Is it realistic? Well if Motorola cana chieve it then so can any one. One thing that came out of the plane excercise is that practice makes a man/ woman perfect and using all the tools seen in the presto pizza case can help us achieve six sigma. But it does look like a process which would take a long time to achieve.

PEUSS project has been very interesting. Dfma, dfr, dfm, dflc has many interesting tools I got to learn this week. Well I have been sick this week but do somehow manage to go to class most times. I did miss Pauls lecture which Louis seems to be quite fond of this week. I am hoping I get well before my presentation this friday and also have facs to work on.

My group members have been very supportive of me when I am sick and would love to thank them for being understaning.

Other thing on my mind is the facs pma. I think I learnt my lesson this time for doing last minute work. I am sick so I wonder how will I manage facs. Lets see!! Time will tell.........

February 02, 2009

Sometimes this world looks like an unfair place

I just heard some bad news. One of my friends lost her mother to Cancer last week.

I wondered why are there so many problems in this World. There are many people dying due to diseases, wars, murders and hunger. There are some unhappy people who do not have a family (orphans) or have been disowned by their families. Then there are oppressed people (women in some culture). Then there is poverty which is another source of unhappiness.

I wondered why they exist. Butr later I realised may be such things make people more human. Many of us are running towards a materialistic life. We want a lot of money, the best of clothes, the best of cars, the best house, good looking girl on....In this process some of us become selfinsh and only think of full filling our dreams. We probably need to remove some time and money for people who really need us.

May be visiting a orphanage once a week is not a bad idea. Donating money to various causes is also a great idea too.....

I hope I practice what I preach. Sometimes I just feel like a machine sitting in front of the computer all day......I should try and remove time......

February 2009

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