January 12, 2013

Combination of DFSS & DMAIC

It can be said that the joint implementation of the DFSS and Six Sigma is important because they augment and complement each other. Understanding how the two work and where they differ in characteristics is very important for the workforce of any organization. From what I learnt I can say that a key element to use or combine both approaches is to understand that DFSS is an inductive process analysis while the Six Sigma using DMAIC is a deductive analysis. Both of them have some limitations that can be overcome using proper techniques from the other one. To explain that I would try to mention some of the approaches limitation and how to overcome them using the other ones practices which might be helpful in future implementation.

1) DFSS procedure does not have a universal application: Six Sigma DMAIC can be used as a complementary tool. This is because the Six Sigma has a standardized way of application, whereas the Design for Six Sigma is customized according to the organization so a company can modify SS in their desire to come up with proper tools. DMADV, DCCDI, IDOV, DMEDI are all modified tools used by companies to apply DFSS.

2) DFSS focuses much on the final engineering optimization processes. This means that the finer details of products and services which should satisfy the customer may be missed out. The use of Six Sigma is important here because it assists in improving the processes which may have been missed out by the DFSS.

3) In a manufacturing set-up, the DFSS can only focus on initiating processes to reduce machine breakdown time. DMAIC goes further to look at different aspects of this machine breakdown before improving on the system. In such a situation, the case will have been dealt with at the micro and the macro scale.

4) Applying DFSS from the beginning will ease the job of defect reduction. A case in point is a defects reduction program in a factory. Six Sigma cannot implement such a process; however, DFSS can implement it easily. Six Sigma can then improve on the process.


Design For Six Sigma

The production of quality goods and services calls for inception of a proper quality management system in an organization. Design for Six Sigma and Six Sigma are some of the quality management tools which ensure that customer satisfaction are met through the effective and cost-efficient provision of goods and services. From what I have learnt I found out that Design for Six Sigma is a relatively new concept which was created to support the Six Sigma tool of quality. The two differ in definition and function. Six Sigma is only used when there are processes already put in place. Design for Six Sigma determines the needs of businesses and customers, and creates solutions by integrating the relevant processes. It is concerned with the generation of processes rather than the improvement of existing processes. So from companies prospective I can say that, while thinking about building a process and designing products and services DFSS is the right approach to use since it draw a flow line from the design stage till the products and services are delivered to consumers. Through reading and searching many books and articles about successful businesses, it is logical to say that no matter how good are your products; they are useless if customers do not buy them. DFSS approach is trying to measure VOC from the design stage to build a strong customers desired products & services so companies won’t be straggling to sell and survive later on.


December 31, 2012

Measuring Training Returns

Training seems to be a matter of money waste in many companies point of view. Six sigma & Lean as well as any other new introduced systems will require some training to staff. The problem is that employers think that although training upscale an employee skills, it give him or her a better chance to leave to other places. Well such thoughts are good to be considered, not to avoid training, but to find a proper way in reducing turnovers. My point is that training is important to build strong and confident employees. Its benefit won’t be numbers and immediate financial figures, but it can be measured differently. For example having a case of employees receiving training and leaving the company!! Looking at the bright side, your company reputation is growing on the market for creating such experienced staff. Also looking at how employees deal with things after getting well trained might bring some satisfaction. In simple words, setting proper measuring tools might change people ideas about many things “training in this case” .


December 26, 2012

Is there disadvantages about Lean

Applying Lean system sounds to bring positive results all time. That won't be always the case. If lean is seen as a tool (not as a whole state of beeing and thinking) lean is like a sword, which can cause a lot of damage and suffering. Focusing only on reducing cost might lead to job cutting which will effect people involvement and increase resistance against Lean, whereas if lean is used to enhance product or service value, if it is focussed on the constraint and thus enhances throughput while raising productivity and reducing cost, it will cause a chain reaction of raising demand and competitiveness of a company. Therefore these things can not be considered as Lean fault as a system!! In my point of view I believe that they are kind of negative potential outcomes or obstacles rather than saying they are disadvantages. Lean system is some elements that can be filled from elsewhere such as Systems Thinking or the Theory of Constraints to support overcoming implementation obstacles. A good practice might be to let a group - employees for example- to figure out some future seen barriers and ask them in turn and list them on a flip chart being careful to identify each bitch/moan/obstacle with the name of the person that brought it up. Then asking them to come up with solution that each person answer his own problem. By doing that you will have both back up actions for particular problems with significant simplifications.

Lead Time

One critical issue was facing me in my past career was how to improve respond to customers needs and orders. Our focus was in enhancing technology we used and maybe modifying products we delivered. One great and interesting tool can be used in such situation is Lean. It focuses in reduction of waste and improving the Lead Time in order to achieve quicker respond, business setup and reduce delays as well. This is done that Lean investigates processes in deep to take out any non value added steps to have a smoother easy process with less cost and effective manner. By implementing Lean a company will become far more competitive in both the prices you can charge and the effectiveness of the services that you can offer thus enabling you to win more business and grow your business further.

December 16, 2012

Employees & New Systems

The introduction of systems such as Lean and Six Sigma approaches might appears to some people as getting rid of old used system in work fields. This might lead to employees rejecting them in order to keep what actually they think they are experts on and better known by them. Wise management and leadership actions should be taken to such situations. Using both Six Sigma & Lean require a high employees’ contribution for them to succeed. Therefore a good point to bear in mind is for the managers to communicate with their staff to clarify the importance of switching to these systems and the why they will be applied. The big challenge facing the companies is getting managers who have the persuasion and leadership skills to overcome the employee resistance.


Data Base Importance

A good assured data plays a major role on maintaining a sustained business as well as makes the companies’ chance of continued growth when there is an economic crisis higher. It might not ensure the sustainability of the business but they are necessary in applying different improvement techniques, such as Six Sigma, which make the improvement process much easier and makes the goals more likely to be achieved. This kind of information helps in knowing some of the fundamentals of building a new business bases so that introducing a strong data base and select a proper improvement tool to help to improve and meet the market requirement.


November 29, 2012

Performance vs Variation

From Taguchi methodto improve the quality of manufactured goods, it noticed that consistency of the product is more vital than its actual performance during testing. Bear in mind that users are going to make use of it under different circumstances not like to those perfect laboratory testing standards. In simple words, a product that can handle various conditions and perform well with less variation is better than a product performing excellent with great variation when conditions changes.


November 28, 2012

Is My Process UNDER CONTROL !!!

People have different views about achieving the products’ specifications and keeping their processes under control. One great example and could be the believed as the secret behind the Japanese success is the amount of excepted variation during the process. There was a case about a failure happened to the collar machine in their process and they figured it out, but they kept using the same machine for about 24 days waiting for the new collar to be delivered. The amazing truth was that even with their machine failure and the variation gone out of control, they were remained producing their products within the customers’ specifications, how amazing is that!!! In other words, they were producing their products in a very small variation that even when the things went wrong they stayed under control. This is a real great lesson to think deep about how far your process is under control and when to say we are producing just fine.

Very Interesting


Great Book about lean

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THE MACHINE THAT CHANGED THE WORLD offers a groundbreaking analysis of the entire lean business system, including product development, supplier management, sales, service, and production - an analysis even more relevant today as GM and Ford struggle to survive and a wide range of British and American companies embrace lean production. A new Foreword by the authors brings the story up to date and details how their predictions were right. As a result, this reissue of a classic is as insightful and instructive today as when it was first published.


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