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Lean Six Sigma

Toyota Production System – Early History – Part 1

March 30, 2017

The Toyota Production System (TPS) was not hatched on the manufacturing floor nor any university. TPS is a result of the history of Toyota. The TPS was forged on economic, competitive and people’s push on the Toyota Company. We believe the best way to understand the TPS is to discuss it in the context of […]

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Lean Six Sigma

Perfection

March 27, 2017

If you are operating today exactly the way that you operated yesterday, how will you ever achieve perfection? Perfection is not achievable because what is perfect today is not perfect tomorrow so it is an ever changing target. However, some of the very best companies are continuously chasing that target. If they are operating closer […]

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Lean Six Sigma

Push Authority and Responsibility Down the Chain of Command

March 23, 2017

Work is not progressing as fast as you’d like. Time is misspent either in meetings, or making decisions regarding simple things, or you’re fielding questions constantly during the day because you are the one with all the answers. That is the challenge that is usually seen with a Control Freak. If you believe that you […]

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Lean Six Sigma

Pull vs Big Batches

March 21, 2017

A business wants to focus their product or service on customers that have asked for their products or services. Currently, the business approaches satisfying their customers in terms of large batches. That means that you produce your product or service in a large quantity and then store it in preparation for delivery to your customer. […]

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Lean Six Sigma

Parametric or Non-Parametric

March 16, 2017

Your manufacturing business uses statistics to measure its performance. There are a wealth of statistical tools out there and all of them have preconditions that let you know how capable the tool will be. One of the most important preconditions is that the inference or population data is normally distributed. The fact of the matter […]

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Lean Six Sigma

Flow

March 13, 2017

When we talk about flow what exactly are we talking about? Whether you are in the service industry, manufacturing industry, or medical industry, flow refers to the movement of either product, service, information or anything in your organization that goes from one place to another. The inhibitor to flow is waste in Lean Six Sigma […]

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Lean Six Sigma

Hard Dollar vs Soft Dollar Savings

March 12, 2017

Hard Dollars or Soft Dollars. Which is best? Both of those dollars represent a savings to somebody. Let’s discuss them in a little more detail. Hard Dollars Hard Dollars are dollars that you can actually see in a budget. These Dollars are savings that you can actually quantify either now or into the future. These […]

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Lean Six Sigma

If You Run at 6 Sigma How Come You Test at 4.5 Sigma?

March 9, 2017

If You Run at 6 Sigma, How Come You Test at 4.5 Sigma? If you believe you have a 6 Sigma process, in other words 3.4 defects per million opportunities (DPMO), do you test at 4.5 Sigma? I’ve always wondered what the value of the test is when you never exceed the test value. The […]

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Lean Six Sigma

Theory of Constraints

March 6, 2017

Every Value Stream (a look from customer request/order all the way through to delivery) has a constraint. Constraints by definition are the process, which if the Value Stream were accelerated, would start to have Work In Progress pileup in front of it. The constraint is not always obvious and is only seen with a complete […]

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Lean Six Sigma

Inspection vs Prevention

March 3, 2017

100% inspection is at best 80% effective. Businesses that use inspection to drive in quality for their customers pay a heavy price for doing this. If you’re running at six Sigma that means that you have 3.4 DPMO (Defects Per Million Opportunities). This is a rate of one defect per 294,000 opportunities. How will you […]

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Lean Six Sigma

Value Stream

February 28, 2017

Attain Profound Knowledge of Your Business/Manufacturing Systems Current Situation The Rolled Throughput Yield (RTY), which is the percentage of the original product or service that makes it through the business system within specification, is an important metric for all companies. The Takt time is the time that sits between products or services delivered to a […]

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Lean Six Sigma

Design of Experiments (DOE)

January 10, 2017

The process no longer generates optimal output, but it used to.  Design of Experiments is the solution.  On day one inputs were optimized but all mechanical processes degrade over time and input values have not changed since the process started.  You know the output is no longer optimal so what do you do to compensate […]

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Lean Six Sigma

TRIZ

January 9, 2017

The Key to Concept Generation – TRIZ, A Lean Six Sigma Tool The business has a product they are developing that has inherent contradictions.  An example of a contradiction could be volume of an object vs. the weight of an object.  Or the speed of a product vs. the temperature of the product. Needing to […]

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Lean Six Sigma

Business Agility

January 5, 2017

Developing Business Agility in your company is not a fast process, which is exactly the reason a business needs to start right now. Toyota did not get where they are by sitting back and waiting for innovation. Innovation will come but in the meantime, lay the groundwork. The drive to excellence requires three different game […]

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Lean Six Sigma

Failure Mode and Effects Analysis (FMEA)

October 28, 2016

There are two types of Failure Mode and Effects Analysis (FMEA).  One is referred to as PFMEA or a Process-FMEA and that is the one we will focus on here. The other is a DFMEA or Design-FMEA which is very familiar to the PFMEA but won’t be discussed in this blog. The situation is that […]

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Lean Six Sigma

Should a Company Manage by Value Stream?

October 10, 2016

First of all a Value Stream is a way of looking at your company’s ability to deliver, from start to finish, a product or service. For instance, let’s say that you are manufacturing and selling a stapler. An example Value Stream for a stapler could start with a customer, let’s say the customer is a […]

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Lean Six Sigma

Statistical Process Control Challenges

October 3, 2016

In the world of Statistical Process Control there are two things you know for certain. First is that every manufacturing process that has machinery involved is constantly degrading.  Therefore, the quality product produced is losing a little bit of quality every day. Secondarily the charting test (examples are WECo and Nelson rules) that is performed […]

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Lean Six Sigma

Business Planning

September 27, 2016

Ho hum – it’s time for Strategic Planning. We already know what the CEOs goals are, now is the time to build the strategies to accomplish those goals. How about we just do what we did last year? Business goals should not change quickly so that may be a reasonable question. Certainly if you have […]

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Lean Six Sigma

Quality

September 19, 2016

“QUALITY IS FREE – The Art of Making Quality Certain” Philip B. Crosby wrote the book with this title and published it in 1979 (NAL Penguin). And still, companies don’t get it. Lean Six Sigma is all about quality. In fact, it is possible to build in quality, speed the delivery of products, and decrease […]

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Lean Six Sigma

Confidence Interval Overview

September 12, 2016

The Confidence Interval might not be what you think it is. It is NOT the probability that the true population parameter is within the calculated sample Confidence Interval. Let’s start at the beginning. The area of statistics that this applies in is called Statistical Inference. This is the case where it is too onerous to […]

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