1. Six Sigma, JIT and Kanban

2. Six-Sigma
Based on three concepts – Quality Control, TQM and Zero-defects
Six Sigma or 6 σ is expected to have % 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

3. 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

4. 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

5. 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

6. 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.

7. 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