Lean Manufacturing, which stems from Toyota Production System, is focused on process flow and lead time and views any activity that does not add value as waste. While Six Sigma is problem focused and it assumes that process variation is waste because it generates defects and COPQ (Costs Of Poor Quality). In the first years of 2000 Six Sigma encountered Lean creating ‘Lean Six Sigma’. Nowadays it is considered a well-established system for process improvement as confirmed by many companies. The marriage seems to be happy. Indeed it combines the ‘speed’ introduced by Lean, and Six Sigma capability of reducing variation.
By means of the tools and principles of the Lean Six Sigma, Chiarini & Associates provides services such as:
- Improvement of Product/Process design and development
- Time-To-Market reduction (Lean Office)
- Project Management
- Variaty Reduction Programme
- Design For Manufacturing and Assembly
- Design For Cost
- Product/Process Reliability
- Robust Design
- Lean Manufacturing
- Lean Office(also for service industry)
- Supply Chain Management
- Supplier rating
- Kanban and order management
- Icoming and Oucoming logistics
- Audit for developing suppliers
- Six Sigma and Design for Six Sigma (with Yellow, Green and Black Belt certifications)
- TQM – Problem Solving, FMEA, SPC, DOE
Lean Manufacturing – Lean Office - Toyota Production System
Lean Manufacturing leads to increase profitability reducing wastes and lead-time. Lean can be applied also in office processes and service industry (Lean Office).
- Value Stream Mapping
- Takt Time calculation and order management
- 5S and standard work
- "U" shaped cells and one-piece-flow
- WIP reduction
- Total Productive Maintenanca
- SMED for set-up reduction
- Poka Yoke
- Heijunka levelling
Chiarini & Associates has been one of the first consultancy firms to introduce the innovative tool ‘Makigami’ for mapping transactional process such as Design, Marketing, H&R, Order Entry, Accounting and Finance, etc.
Find more about Lean Manufacturing at Leanmanufacturing.it.
Six Sigma tends to cut down COPQ , this is what Six Sigma does better. The DMAIC pattern is perhaps the most important part of Six Sigma DNA. DMAIC is something unique and it helps in the deployment of projects without failures; every stage, from Define to Control, is validated through a ‘tollgate’ check, which can stop the project if the result stage is not what is expected. Design processes are instead well managed using the DFSS pattern. Within the DMAIC pattern, Six Sigma teams can use numerous tools dependent on the scope and the kind of stage. Among these, Six Sigma inherits well-known quality management tools including advanced statistical tools usually managed by statistical software like Minitab. Six Sigma has also borrowed tools derived from Lean. The DMAIC toolset is very open and can be surely enlarged in the future. Six Sigma has a strong approach based on facts and data. All the project results are validated using ‘sigma level’ around the target. In several companies, the finance department is assigned by the Sponsor to calculate and report these savings to senior management.
The most important figures are the Master Black, Black, Green and Yellow Belt.
Chiarini & Associates using the traditional GE scheme as well as the standard ISO 13053 can certify these figures and train them using the most used statistical software Minitab®.