The basic philosophy of Lean is the elimination of wastes. Six Sigma provides a structured statistical way to evaluate how a process behaves over time. The combination of both disciplines (Lean & Sigma) focus on 3 key steps (standardization, stabilization, and improvement). A seamless integration of both disciplines enhance the rigor of drilling down to the focused few KPI's (key process inputs). IDM provides the knowledge and strength to apply the right problem solving tools to fit your timeline and investment. We also can tailor the appropriate depth of tool sets to match the practical background and interests of your team members. Our experience working with different nationalities, ethnics origins, native languages and cultural diversities, can elevate your success level significantly.
The implementation of a robust LeanSigma continuously program must start with a solid foundation of 5s and visual management. Investments in people development and LeanSigma skill training are essential in moving up the levels of continuous improvement.
VSM’s are stairways for advancing to different levels. Visual workplace starts with real time production status which is reported by team members on Hr x Hr charts and SQDC boards on the shop floor. This drives timely feedback and collaborative corrective actions at the front line. Management must participates on daily Gemba walks to review shop floor SQDC boards and trend charts in the War room. Corrective actions are tracked. A more deep rooted problem requires a dedicated Kaizen event to fix it with a high sense of urgency. Usually the site Lean Champion or trained KPO Technician would lead such a Kaizen event with a clearly defined project charter. IDM can help your team to customize a roadmap for your respective business needs.
In order to have a comprehensive understanding of a current state of a process, IDM uses the statistically relevant sample size to characterize the stability, normality, spread, and capability.
addition, we also use Lean time observation to identify the Takt/cycle time gap, waste opportunities, safety hazards at the Gemba. Shifting the paradigm from decisions based solely on opinions to data is a starting point. We emphazise on the discipline of using A3 (Lean) or DMAIC (Six Sigma) methodologies for formal problem root cause analysis to sustainable solutions. Simple and effective problem solving tools are often more impactful for team members at the frontline. IDM provides the depth of knowledge and experience to guide you through this land mine.