Lean as a management philosophy based on the “Toyota Production System” is prevailing over all conventional hectic procedures & methods, which in turn impart no value in the final product. Toyota became the market leader by deploying this philosophy in a real-time scenario within their systems.
The idea which is acting as a driving force in the exploration of this technique is to focus only on core activities which are adding value in the final product, for the end customer. All the processes, systems, parameters & products will be designed and verified by taking into account end-customer needs. Any other activity which is not enriching a product or service in a valuable manner must be abandoned as quickly as possible.
Lean is like a religion driven by a human mindset and strategic tactics. Production and service activities are analyzed in the light of value addition contents. According to the Lean approach, the performance of all other activities and processes in the company, which do not add value for the end customer, generates costs and are considered unnecessary losses. The Lean transformation approach aims to eliminate or significantly reduce those losses. In more simple words, Lean Transformation leads to more value with as few resources as possible.
A Lean company is aware of what is valuable for the customer and focuses its key processes in this direction. The ultimate goal is to deliver perfect value for the customer through a process with zero waste.
When eliminating waste from the value-adding stream, the management should not eliminate elements of it but set up processes, which require less human involvement, less space, less capital, and less time for products and services creation, which cost much less and have fewer defects as compared to the traditional business systems. The companies can then respond to the ever-changing client requirements with a variety of solutions, high quality, and low cost, and very short production time. In addition, information management becomes easy and precise.
Six Sigma is a well-structured, data-driven methodology aiming towards the elimination of variations, imparted due to product, processes, or systems in all kinds of manufacturing, service delivery, management, and other business activities.
Six Sigma methodology is based on the combination of well-established philosophy, set of tools, methodologies & metrics, enabling the organization to see the hidden defects factory. Six sigma is perceived as a myth by many traditional or conventional practitioners of quality systems due to its 3.4 defects per million methodology. Though, it only makes the processes play in safe premises where defect & variation would be minimum
Six sigma, as a philosophy, is a true measure or control of equation Y=f(x). It generally depicts that by controlling x inputs which are transformed into Y output through function f, we can achieve excellence. Also, it is equipped with advanced statistical control tools which are very helpful in the data analysis to see the cumbersome event in a crystal clear view.
As far as methodologies are concerned, it deals with DMAIC & DMADV techniques, each with its own perks. Lastly, it is a measure of metrics that are set for any process or system.
Due to its highly efficient impact, these methods have recently become very popular in the USA, Germany, etc. Even in 2007, General Electric published the report listing the savings of almost 1.6 billion due to six sigma
Integration of Lean Six Sigma
We passionately help you in building blocks for achieving efficiency parameters. Though, depending upon the scenario and future impact, an organization can have any of the following two options,
● To engage your own internal pooled staff for carrying out the projects
● Engage our personnel to identify potential areas of process optimizations and establish the required benefits.
The integration of Lean Six Sigma could be depicted as;