Highly successful corporations vary their manufacturing SOPs. What they have in common is the use of tried and tested quality control and assurance methods such as six sigma, lean, and kaizen.
In this article, we’re going to talk about the top three manufacturing philosophies and practices. We’ll also give you a viable solution on how you can digitize these practices for your organization.
1. Six Sigma
Six Sigma is a set of quality management techniques that aim to reduce defects in manufactured products by identifying and removing the root cause of errors. The key to six sigma is its focus on preventing defects rather than simply detecting and correcting them after the fact.
For instance, a complete in-general process must have a maximum of 3.4 defects per million opportunities to be considered “Six Sigma Quality.”
Six Sigma Methodologies
DMAIC (Define, Measure, Analyze, Improve, Control)
DMAIC is a project management method for improving an existing process. It includes the following phases:
- Define the problem, what needs to be improved, and how the goals for improvement and customer requirements.
- Measure key performance metrics.
- Analyze root causes of poor performance.
- Improve the process by implementing solutions.
- Control the process improvement and future process performance.
DMADV (Define, Measure, Analyze, Design, Verify)
DMADV focuses on the process of designing a new product, service, or process and incorporates these phases:
- Design products that meet customer needs and the organization’s identity.
- Measure and identify how the product, service, or process impacts quality. This includes risk and production capabilities.
- Analyze objectives to maximize design.
- Design, develop, and test the product, service, or process to make it more effective.
- Verify design through rigorous testing.
2. Lean
Lean identifies the presence of and eliminates seven specific wastes mentioned below.
- Overproduction – Creating more products than is necessary or can be sold
- Waiting – Time spent idle waiting for the following process
- Transportation – Unnecessary or excessive movement of products
- Inventory – Excess or unnecessary inventory
- Motion – Unnecessary movement of people or equipment
- Defects – Products that do not meet customer expectations
- Overprocessing – Applying more resources to a necessary product
Tools
Numerous companies apply Lean principles to their operations. Below are the most widely used tools and techniques for practicing lean.
5S (Sort, Set in Order, Shine, Standardize, Sustain)
- Sort – Identify what is necessary or appropriate and discard everything that is not.
- Set in Order – Organize, arrange and store your items, so they are all in their correct places.
- Shine – Have an organized, clean area for safety and inspection.
- Standardize – create a work area with the three steps to create a standardized one.
- Sustain – Make plans to update and maintain the consistency of procedures.
PDCA (Plan, Do, Check, Act)
The PDCA technique takes place in a cycle designed to solve industry-wide problems.
- Plan: Identify the problem, establish goals and objectives, and develop an action plan.
- Do: Implement the plan and collect data.
- Check: Analyze the data to see if the problem has been solved and identify any areas for improvement.
- Act: Take corrective action as necessary and continue monitoring the situation.
The PDCA cycle can be used for problem-solving, from personal issues to business process improvements. It is a simple yet effective way to help you focus on what needs to be done to reach your goals.
5 Whys
Toyota pioneered multiple manufacturing and management models. These business standards are often found in organizations like 5 Whys. Lean is used to find the root cause of a problem using a technique called 5 Whys.
3. Kaizen
Tools
Here are some of the most common Kaizen tools companies use:
SIPOC (Suppliers, Inputs, Process, Outputs, Customers)
SIPOC is a tool for ensuring clarity in process workflows. This helps eliminate redundant efforts and identify where people struggle to complete their duties.
Furthermore, it helps to increase accountability as well as decrease overall efficiency.
Gemba Walk
Performing a Gemba walk is an activity that executives should make part of their routine, as it will ensure that upper management can observe their staff’s processes and identify opportunities for improvement. It also helps ensure that upper managers learn about the actual work rather than simply commenting on individual performance.
We have developed an easy-to-use Gemba walk app for organizations to streamline the Gemba walk process for manufacturing operations. The app helps manufacturers to identify key improvement areas. Companies can work through Gemba walk checklists to capture first-hand observations, gather information, collect digital notes, and conduct walkthroughs of manufacturing sites & shop floors.
You connect with us here for detailed information about our Gemba Walk App
8D Report
The 8D Report is a problem-solving technique used to contain, resolve, and prevent process issues. The method was initially only used in the automotive industry due to Ford’s influence but is now widely used in various industries, including manufacturing, healthcare, and retail. The strategy includes using experts, data analysis tools, management solutions, and validation of collected data.
Axonator for implementing Quality Control Methodologies
Manufacturing organizations across the globe can use Axonator for digitizing quality control operations like quality audit, quality inspection, and more. Fortune 500 firms have used our no-code platform to ensure high-quality standards of products and services. Our no-code platform has tons of features to ensure that the platform will meet the end goal of the company.
Why Axonator?
- World’s first mobile-focused & Highly customizable no-code architecture to support real-world scenarios.
- Deploy enterprise-grade solutions rapidly as per unique requirements
- Achieve paperless quality audits and inspections
- Generate reports automatically and automated data collection for trends and analytics
- Streamline processes and implement a fully automated system within weeks using Axonator’s MicroApp strategy.
Axonator offers several simple and ready-to-use enterprise-grade apps for field workflows like inspections, audits, safety, asset management, and work orders that organizations can use to replace paper, spreadsheet & cumbersome desktop-based manual processes with mobile & tablet apps.
