November 28, 2013

Six sigma deployment in manufacturing

The six sigma is the way that helps to solve the problem in the process in both of service and manufacturing. Moreover, it supports the organisation to be continuous improvement also. In the industry, it assists to improve in both of organisation capability and product quality.

There are several methods for applying the six sigma. First, select the priority which is the biggest negative impact. After that, creating the project charter to understand the problem and forming the team which has a variety of function which involves with that problem or process. We should define the SIPOC. This could help to provide the common view of process and problem. Furthermore, we should find the special cause by using control chart and find the root cause by fishbone diagram and see the significant cause by pareto.

When we can reduce the variation in the process. We could apply DOE (Design of Experiment) to find the optimisation factor which can produce the product in the good way. It could be used by determining the significant factor with the team and see the relationship between the factor by using the result of the experiment and finding the average of each factor to see the optimum point of product. In addition, we should define the action plan to implement, set the standard procedure and monitoring the process.

It could be seen that the six sigma is an important method that could make the company success in the business by facilitating to develop the quality of product, save the company expenditure and design the optimum process.


November 26, 2013

Japanese control chart

Japan is the first country, which uses the control chart to monitor the process or listen to the voice of process. It means that it is used for detecting the process change and problem prevention. When there is some point, which is out of the control limit, it means there is some factor that changes from the normal. We should verify the root cause of it and solve it. We can verify the root cause by using cause and effect diagram, and that would be easy to tackle that problem.

It can be seen that using the control chart in the process helps to provide the real time data. That can make us to know the problem and solve it in time. Moreover, in terms of communication, it assists to communicate the voice of process to the organisation.

However, as the control chart will have the UCL (Upper Control Limit), LCL (Lower Control Limit) and average to control the process, it could be recalculated in some cases. First, the process voice illustrats that it change. Second, there are 8 points which are under the average line. It could mean that the firm makes some changes in the process or there is no change, but the process is shifted.

In conclusion, presently, the control chart is widely used in many industries, which are service industry and manufacture industry. It is one of tools, which uses for improvement the efficiency and effectiveness. Furthermore, it could drive the company to be the continuous improvement organisation.


November 25, 2013

Improving production line

The production line is the key thing to create the customer value because it is a main thing to judge that the company could serve the product to the customer in time. It could do in step by step.

First, we should determine the target time per piece, which we should produce from the demand of customer and working time. This can be called takt time. After that we should define the time of each operation to see which process could be combine together. At the same time, we should observe the operation to define the waste, which consists of overproduction, overprocessing, inventory, motion, waiting, defect, and transportation. When we know it, it would be easy to improve to get the operation time as takt time. We can use the cause and effect diagram to see the root cause of each problem which occurs in the line. Moreover, we use flow chart and SIPOC to evaluate the problem. In order to calculate the time, it can make us know which process should be improved. We can see that the line has not balance yet. So we should balance the work by using the time and balancing the activity by combine some process together or seperate some process away.

For the waste, there are many ways to reduce the waste. For example, in case the operator has to walk to pick some material, we can eliminate it by preparing the material in each station to make them easy to use. in case of motion, this can be solved by using the ergonomic to allocate the material to use in each station. For the inventory, we could use the pull system to reduce the inventory in the production line. In terms of, overprocessing and waiting, we also use the line balancing to balance the work. On the other hands, the overprocessing also uses the ECRS (Eliminate, Combine, Rearrange and Simplify) to tackle this problem.

It could be seen that this thing would be important to the organisation to improve the line to meet the customer expectation. However, there are many ways to solve the waste such as 5R, ECRS, scheduling, production planning, KANBAN, etc. This depends on companies to select which solution is suitable for them.


November 14, 2013

Organisation Excellence from six sigma and SoPK

Organisation will be excellent when it concerns on internal and external. For the internal, improvement plays an important role to make the firm excellence. However, to compete in the market, the company should realise in customer satisfaction which is the external also.

For Deming theory, the system of profound knowledge is the thing that can improve in external and internal aspects. There are 4 components in the profound knowledge which consist of appreciation for a system, theory of knowledge, variation and psychology. The appreciation for system, this means the inside organisation should work together not compete each other. Furthermore, this component suggests that the firm should have the aim and good leader. In term of theory of knowledge, it emphasizes on the theory since if there is no theory, there is no improvement. This can do by using PDSA (Plan-Do-Study-Act) to implement. In variation, this mentions in special cause and common cause. Nevertheless, in this theory, there is no specific tools provide to reduce variation. Finally, psychology, this focuses on the employees in the organisation whom the leader should concern and build the intricsic motivation for them.

For Six sigma, It is the thing that used to improve the quality in term of DPMO (Defect per Million opportunities) by using DMAIC (Define-Measure-Analyse-Improve-Control) method. This concerns in the customer more than intrinsic in organisation.

It can be concluded that both of them are the things that support each other to build the continuous improvement organisation. Futhermore, These can make the short term process that can use in the long term. In term of improvement, as the Deming theory does not provide the exact tools to use, the six sigma suggests the method to do. Moreover, as the profound knowledge concerns on people while the six sigma does not. That means the profound knowledge can help the improvement in six sigma success in term of employee's intrinsic motivation. Therefore, integrating the profound knowledge and six sigma are the things that can help the organisation excellence in many ways.


November 12, 2013

Cause analysis in control chart

The control chart is used for controlling and measuring the process in term of variation by using the UCL (Upper Control Limit) and LCL (Lower Control Limit) to define the range of acceptable. The variation occurs in everything. This happens from common cause and special cause. The common cause is the thing that you can see it happen usually such as the machine stops because it has to preventive maintainance. On the other hand, the special cause is the thing that happens by accident such as machine stops because it breaks down. These causes make the out-of-control situation happens. To set the control chart, the common cause should consider in the range of spec while the special cause is the thing that we have to find and fix in term of out-of-spec.

It is the fact that the control chart relates to the normal distribution. In case of special cause occuring, the normal distribution will shift out of average. This can apply to use for analysis the root cause of problem, supporting the improvement in organisation and maintaining the quality of product as well.


November 11, 2013

Benefit in developing transformation program

Today it is my first day to study the six sigma class. I study about the overview of using the six sigma to improve the process. I found that there are many principles to develop and apply to make the organisation better by using statistic, lean manufacturing, tools including the Deming cycle (PDSA). This make me know the concept in six sigma. It is the fact that six sigma aims to reduce the defect in term of defect per million opportunities (DPMO), but in some products, six sigma is not right to do. Therefore, the company should consider their products and organisation before they apply. I see that this is so benefit for me in the future.

Especially, I found that in term of transformation program, we should integrate the aspects about the possibility of achieving in the business goal, Making sure that line leadership is engaged, change plan development, people selecting, using the systematic,consistent and methods, training in the job in hand, suitable project selection, supported and accounted by the leader, recognising and communicating in achievement and learning together. After that we should use the PDSA to implement it. In this section, I see that it is very useful. I can use this to implement in planning the project in the future. As I have ever worked in the improvement project before, I see that this section is very crucial because I have ever faced the problem during work the project and it is so hard to solve it. So I think that it would be better if I did as this theory, I would not have the problem in that.


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