We can learn the PMI process improvement yellow belt course online before the module starts, but I have not finished all of it, and some knowledge is only known but not used. After doing the exercises to improve the assembly process of the model aircraft, I revisited the online yellow belt course and realized how many methods are actually used in practice. What steps should be taken to solve the problem? After finding a lot of similar points, the understanding of PIUSS is even deeper.
First, the DMAIC cycle is the most important part of the six sigma, and all process improvements are based on this cycle. People will instinctively think of solutions when facing problems. But this is not applicable in Six Sigma. When the problem arises, the first step we need to do is to analyze the entire process to find the cause of the problem and choose the part that will be prioritized for improvement. In this step, fishbone, flowchart, SIPOC, and Pareto diagram and so on can be used.
The next part of the focus is on defining waste. Because our goal is to shorten the delivery time of the aircraft so that it meets the customer's requirements. Waste has a big impact on delivery time, so reducing waste is a major measure.
Transportation takes a lot of time in this process when people stand up and go to another table to get component.
Motion is also a waste because some components fall down the table.
Over-processing: get the wrong components so go back again.
Inventory & waiting: the different pace of different operators, so some operators finish quickly and many planes are waiting in the process.
Defects: a wrong assembly will lead to more time to repair it.
Nearly all the wastes occur in this process, so when we look at these operations according to the kind of wastes, we will identify which part should we improve clearly.
Then, some small changes in design or supply will help a lot. A reversing screw makes assembly easier and more successful. Choose a person to supply parts specifically so that other workers no longer need to spend transportation time.
After the above steps, we got a new plan and then we move to the Improve stage. Test, study results, and modify the plan, and test again...until the results meet customers' requirement. And then standardise.
Besides, another important factor in this exercise is the balance of each operators' workload. The delivery time is determined by the longest time by operators, like the Cannikin Law and TQM.
Last but not least, we can't forget the review phase. The review includes the improving methods and teamwork aspect. What I'm doing now is also a kind of review~~