Six Sigma, JIT and Kanban

Six-Sigma Based on three concepts – Quality Control, TQM and Zero-defects Six Sigma or 6 σ is expected to have 99.99966% of products manufactured free from any defects or expected to have 3.4 problems-per-million products manufactured Two project Methodologies DMAIC: Define, Measure, Analyse, Improve and Control DMADV: Define Measure, Analyse, Design Verify

DMAIC DMADV SIMILARITIES The first 3 measures are the same Data Intensive Use of statistical tools Implemented by Green belts, Black Belts and Master Black Belts …used when product/process in a firm does not keep up to customers’ specification or not performing adequately …used when product/process does not exist OR with or without DMAIC still does not meet customers’ requirements DIFFERENCES DMAIC is about continuous improvement whereas DMADV is about Re-engineering DMAIC provides structure and rigor to problem solving while DMADV drives customer needs into product and service design DMAIC is correction while DMADV is prevention DMAIC projects often take short durations to fix a problem while DMADV take long durations as they are based on long-term business needs for new products/service

Six-Sigma Criticisms Offers nothing new Overselling of Six-sigma through certifications that claim expertise but having only basic knowledge More of a corrective method than being proactive Rigid because of its attention on variation Limited success and no long-term improvements proven Processes cannot be normally distributed in the long-run

Just-in-Time and Kanban Kanban means “signboard” or “billboard” JIT can be achieved through Kanban Kanban is signalling the scheduling system for JIT production

A Switchgear Unit in Nashik Switchgears are electric power systems One entire product was made from start to finish by one cell combined with concept of kitting (providing enough material to reduce wastage) One shop had a board with different-colored bulbs that indicated the reasons for various bottlenecks. For instance, if there was no material or no order, a red bulb lit up; if the basket was full, a yellow bulb lit up, and so on.

Kanban, JIT in real-life? Done To-do List In Progress Basic Principles Visualize workflow Limit work-in-progress Pull work from column to column Monitor, adapt, improve