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Lean and Six Sigma

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With the changes in the global market scenario and the increasing competition, the manufacturing organizations face a constant need for improvement. The manufacturing paradigm has shifted from craft manufacturing to mass production and more recently to a newer approach – the lean manufacturing. In mass production, large quantities of the product were produced and the focus was more on quantity than quality. But with the increase in competition and the gradual saturation of the market the need to develop a new paradigm that focuses more on the process i.e., improved quality, delivery and cost performance has emerged. This has led to the introduction of Lean Manufacturing which focuses on waste elimination and creation of flow within an organization. In the words of Shigeo Shingo “The most dangerous kind of waste is the waste we do not recognize.”
Lean and six-sigma are methodologies backed by powerful tools that help in improving quality and productivity thereby improving overall profitability and competitiveness. The lean philosophy was initially pioneered by Toyota manufacturing company and aims at various methods of eliminating waste and improving the process flow. Six Sigma on the other hand, focuses on reducing variation using problem solving and statistical tools. It was first implemented in the Motorola Company as a safety margin for product performance.
SIX SIGMA
Six Sigma is a continuous improvement strategy that focuses on minimizing defects and variation and aims at achieving 3.4 defects per million in productions, design and process flow. Six Sigma minimizes variation in the process flow, thereby improving customer satisfaction. Benefits of implementing Six Sigma methodology are as follows: a. Better knowledge of products and processes b. Defect reduction c. Focus on communication and teamwork d. Improved customer Satisfaction e.

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