The DMAIC Process, a Step-by-Step Tool towards Improvement

DMAIC is the very tool that Six Sigma uses in order to achieve its goal and that is to provide optimum client satisfaction. DMAIC stands for define, measure, analyze, improve, and control. These five words represent the five steps that Six Sigma uses in order to eradicate the factors that hinder success and improvement. These different steps must be followed in correct and exact order starting from the define step down to the control part. All these five must not be interchanged. Let us now discuss each step separately.

Six SigmaThe first step is to define everything. This step involves definition of the problem, the customers, the projects, target, and all other factors that affect the process. Defining each factor clearly will guide you all throughout the DMAIC process. Overall, this step is where you clarify everything first before going to the next step. The second step is the measuring or the collection of data. After basically defining the factors, you are to decide now on how and which to measure. At the end of this second step, you will be able to come up with the measurement plan. The third step deals with analyzing what has been collected from the second step. This is where the hindrances are being discovered and analyzed. There are tools for analysis that may be used in this step. These tools will serve as guide towards correct analysis of the data collected. In addition, this is also the step where you choose whether or not you will improve or redesign the process. If it is clear from your analysis that it must be redesigned then you go back to the measure step. If there is no need to redesign, then you will proceed with the next step which is to improve. You can improve the process by simply eliminating the hindrance factors.


Finally, once you have improved the process, your concern is on how to maintain it that way and ensure improvements all the way. This is when you perform the last step which is the control.

The Difference between Lean Office and Lean Manufacturing

What is a Lean Office?
A Lean Office is a place where the best customer service is offered by eliminating all the possible waste during production. It is accomplished by creating a smooth flow of work in the lean office and creating a standardized way of accomplishing work. The lean office operates using the principles used in lean manufacturing.

Lean OfficeLean Office vs. Lean Manufacturing
The Lean Office and Lean Manufacturing have many similarities but there are certain differences that are needed to be pointed out in order to have a more effective lean office.

One of the main differences of the two is the waste it produces. Manufacturing wastes are easily quantifiable and are quite visible. This makes it easier to apply problem solving techniques to lessen the waste. Office wastes, on the other hand, are difficult to spot. Office work usually involves a lot of people making it harder to monitor. It is also hard to monitor the pending work on each work station. Because of these factors, it is more difficult to make solutions to office waste problems.

Lean ManufacturingAnother difference between the two is the culture. Culture can affect the manner by which the company works. The manufacturing culture is informal unlike the lean office culture. Having a formal working environment makes it easier to assign responsibility and define job roles.

Also, it is easier to carry out changes in the lean office than in manufacturing. Changes done in the office are often minimal. Further training could suffice to make these changes. Managing changes and monitoring them is easier in a lean office environment.

The Lean office and lean manufacturing share most of the principles in reducing the waste in the workplace. Both follows the lean principles that started in the manufacturing sector but found its way to the offices and administrations. Although they do share some principles, the differences should also be noted to make a more efficient and effective working environment.

How to Implement Lean Manufacturing

Nowadays several organizations seek to restructure their organizations so as to attain competitive advantage over the competitors through delivering of goods and services by use of less resource to get superiority quality. The aim of lean manufacturing is to streamline an organization in order to decrease wastage by getting rid of unnecessary steps and individuals. Lean manufacturing idea is based on Toyota Production System, that aim to deliver goods and services constantly using appropriate tools, knowledgeable staff and proven methodology.

Lean ManufacturingHere is a guideline to implement lean manufacturing. Get senior management that will support lean manufacturing. The management will implement fully and support the outcome of lean manufacturing. Set the goals to be achieved. To get the support of all workers, tell them reasons for executing lean manufacturing, the way it will bring impact on their lives and what they are required to do. Come up with a team for lean manufacturing. Select a good team leader. He should have good communication skills, charismatic and devoted. The team must include key staff from different departments of the organization, not only the manufacturing department. Educate the team on various techniques of lean manufacturing. Involve a lean techniques expert to train them. Choose the most suitable lean technique for the organization, for instance Total Quality Management, that focuses on ensuring internal guidelines and procedure standards diminish errors and make supply chain management more efficient. Lean technique chosen should be quite simple to implement to ensure success. Prioritize the execution of lean technique chosen by selecting a pilot project. This pilot project must not fail since it is designed to set the lean implementation pace. Roll out your pilot project to various departments. Perform an assessment of the outcome to find out the project success. Identify another project which you will carry out once the on going project is underway. Repeat previous steps appropriate to execute other lean techniques.

How to Get a Green Belt Certification

Six Sigma is an approach which seeks to get rid of variations in the processes of an organization. An organization finishes a project of Six Sigma through data collection on processes and executing changes to diminish variations. Six sigma green belt certification offers knowledge on the techniques used to enhance production through DMAIC model. The training and the course of certification prepares a person to formulate enhancements to procedures, systems and operations. Follow the step below to obtain this certification which will boost your career. Seek the support of the organization you are working with to get green belt certification. This support is vital since many programs will require you to finish a project as an actual test for the certification. Even if there is no project, this certification will not be helpful if your organization is never interested. Get the program which meets your requirements.

Green Belt

Programs of green belt certification are provided by business training schools, a few corporations and quality consultants. They differ from 5-day training to college style program. Other programs are provided online.Register for the program. Go to your manager and the department of human resources to discuss the details and ensure that your organization will take care of your expenses.Take the program and prepare for the exam. After passing the examination, many programs will need you to finish a given project before they give you your green belt.Plan your project. Work together with your manager as well as your colleagues to get an improvement project which you will work on.Use the principles you studied in your class to work on the improvement project. A number of certification programs provide periodic aid through the trainers. They will assist you to complete your project. As well seek support from your fellow workers who have already completed their Six Sigma program. They may act as resource for you by providing the needed advice and help.

Definition and meaning of DMAIC

Dmaic is a six sigma style element which is aimed at improving work, increase efficiency and reduce errors. It has been used by huge companies with huge success. Dmaic derives its name from its methodology and the steps involved. In other words all the five letters have meaning;

Define DMAICD- stands for define which is usually the beginning step in the procedure. It is important to define your company’s goals and objectives which are aimed at meeting your clients expectations. The goals you set should be in line with your business plan. This step helps you not to veer from the main aim of your company. It helps you to stay on course and accomplish your goals and objectives with your clients in mind.

M- stands for measurements; for you to be sure that your goal of error free products has been realized, you must have base measurement. You will have to choose what you want measure and how to do it using dmaic. Be sure that your measurement system is suitable for your overall results. Using the base measurement, you will be able to know whether the defects have been brought down.

A- stands for analyze; whatever information that you gather in the second step is then analyzed to establish the causes of defects.

I- stands for improve; if you need to improve on your production, you will have to consider the previous steps. You can only improve on a mistake that you already know. In that case after putting the measurements in place and doing proper analysis you will be able to reduce errors and waste.

C- stands for control and is the last stage of the process. It ensures that any discrepancy has been dealt with before it affects the process negatively. You need to remember that you will have to continue analyzing and measuring for dmaic to stay effective. You will have to have a well organized layout for you to see continues positive results.

The power behind Kaizen training

The power behind Kaizen training

The Kaizen training method has helped numerous people build upon their business management craft. There are many people who have actually used this method to generate a whole lot of success online. With the wide variety of people out there who hope to succeed even more with their business should consider taking Kaizen and implementing more of it into your daily life. This type of training and traditional development has always been considered as very powerful by many people. It is very good to start using this type of training, and you can easily grow tremendously once you complete the training.

Kaizen TrainingThe power behind taking Kaizen training

Did you know that this form of training has been in existence for more than several decades? Thousands of people all over Asia and the United States were able to grow their business and develop that winning attitude to grow with the help of Kaizen. The most powerful part of this training is the fact that thousands have already benefited from this, and even more people are able to do this because of being online. Kaizen also offers a wide array of training to help in different areas of your life, enabling you to achieve even more success.

Kaizen ManufacturingIt is good to outline that Kaizen can help you learn, develop, and improve your entire business mindset. With so many people who have used this training, it is possible to say that success can be achieved. You can take this training from specialized schools and programs that are beginning to use Kaizen into their development programs. Getting into a certification program to get the ultimate knowledge can be a great idea, but you must know that you can fail if you don’t get the right training. As long as Kaizen is implemented, improvement in your mindset can truly develop.

Learning the Basics of Lean Manufacturing

Lean manufacturing, from the term itself, talks about how to make the most of manufacturing. When speaking about making the most of manufacturing, it simply means focusing on those vital factors that contribute to making the products possible and eliminating on those factors or processes that have little to no importance at all to the manufacturing process. The man behind this amazing concept of lean manufacturing is Henry Ford.

Lean ManufacturingThe question here is, how do you know which factor to eliminate and which factor to keep? The answer is basically simple. You simply have to ask those very important persons in your business. Who are these people? These very important persons in your business are none other than the customers. Try to reach out to them and ask their side. Take time to evaluate which factors are vital in the perspective of the clients. This is a very important step when going for Lean manufacturing because your clients are the most valued factor above all, therefore they must be given the right to speak for themselves.

Lean Manufacturing ProcessWhen you are able to find out the factors that are important for the clients, surely you will be able to figure out those things that are just a waste of your time, money, effort, and productivity. Examples of waste are waiting time, overproduction of goods and services, defective products, overcrowded office, and so on. Just when you thought you have the most efficient business, you will eventually find out that there are a lot of things you failed to look at and these things basically contribute to the slowing down of the processing.

How to Implement a Lean Management System

Excesses in inventory as well as other areas that results to unnecessary expenses in the company while giving no value to customer frequently go unnoticed in an informal manufacturing setting. The lean management system implementation involves the elimination of seven kinds of waste in your business. By getting rid of waste, your business can perform more.

Lean Management System

Implementing lean management system requires many steps to be followed.

Challenge the current meaning of “waste” in your organization. In an informal manufacturing environment, waste is thought as scraps and rework. In the lean management system, it comprises anything which does not put in value to the consumer.

Spot areas where there is overproduction. This is foremost among the seven types of waste which must be removed. The products which cannot be sold as well as those that the price must be reduced to be sold generate waste for your business.

Develop all parts at one point whenever possible. To move a part during the process of manufacturing is a waste of time and resources. In addition, parts can be spoiled during transportation from one point to the next, which create waste as well.

Lean Management ConsultingGet rid of waste. At first, you have to generate processes to ensure there is a single method to produce every part or product. Ensure that there is no room for errors by error-proofing your processes. This will help to eliminate sorting as well as inspection of parts.

Identify unnecessary operator movements which place excessive stress on the body. Perform ergonomic research of your work setting to reduce injuries to employees. This will eliminate superfluous waste of workman’s compensation claims as well as reduce the time and resources that are involved in training the replacement of the injured worker.
Assess specific consumer requirements for every product. Conduct extensive study to find out the processes that add value to your customer.

Diminish waiting time for your workers. Restructure the processes to ensure that your operators do not spent time waiting for work.

How to achieve constant production in an ever fluctuating market?

Product demand will always vary with the newly emerging market situations. In the earlier days, the dominating philosophy was that an assembly line would become more efficient only when skilled employees performed repetitive tasks. The logic behind this concept was to make an employee an expert at one task to increase productivity. But this theory has given way to heijunka for the last two decades and performing multiple tasks have become the need of the hour. When the product line has to shift their focus from one product to another nobody wants to lose precious time in this highly competitive world. Since the demand undergoes tremendous fluctuations a manufacturer will have to be better prepared to face the rapidly emerging situations and that is what makes heijunka an endearing concept to a huge number of people.

HeijunkaA competent production or an assembly line should be better prepared with the production in a flowing and constant manner. The variations in the demand should not affect the output in an adverse manner and these types unexpected changes will be handled inside the production line with heijunka system. The fact of the matter is that heijunka can be put into practice in a manufacturing establishment with highly advanced machinery and an assembly line with the capability of producing multiple products.

Heijunka System This lean tool does not confine itself with manufacturing practices only and it can also be applied in areas like project management, paperwork reduction projects, cost saving measures, and similar business related situations. Anyhow, heijunka was created primarily to address the issues of manufacturing and how to handle the shift in demand by sheltering the production line from the fluctuations becomes a reality with this unique concept. It can be said without any doubt that constant output without having any unwanted delay is the ultimate goal of heijunka.

Job Description for a Lean Manager

Lean manufacturing is making business more effective by getting personnel to work smarter. The process involves keeping workplace in order, ensuring quality product building, removing unnecessary inventory, simplifying and utilizing visualization. The main goal of lean innovation is to enhance employee productivity as well as boost worker contentment by decreasing the work load that staff has to do. At times businesses employ lean managers to run lean transformation.

Lean managerTrade production managers usually execute methods like lean management. Lean manager check everyday processes of a company. Then, he provides workers with consultation and guidance, executing principles of lean management. Lean manager then ensures that the workers follow this system and continue educating workers whenever necessary.

Time is divided for the office as well as production facility. These managers must take time to plan methods of implementing the principles of lean production and must spend a little time sharing ideas with other managers. Crucial time is spent in the business production facility where he oversees production processes and gives training as well. In this setting, these managers are exposed to same hazards the workers are exposed to, although these dangers can be avoided by good safety precautions.

Lean managementLean system is often utilized by manufacturing industry therefore many lean managers require previous experience in the industry. Companies which use lean management processes can also possibly use systems such as Demand Flow, Six Stigma, Visual Management and Just-in-Time. So, managers who possess previous experience are likely to get employed to implement these systems. Skills in communication and presentation are also significant when a lean manager is educating and mentoring workers.

According to Labor Statistics Bureau, the demand for industrial manufacturing managers is likely to decline. The decline is due to overall decline of manufacturing industry because of outsourcing as well as international competition. Nevertheless, the demand for production managers will not drop as much since managerial skills are hard to automate.