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How to reduce manufacturing variations and defects
Six Sigma
The DMAIC method is defined as:
The DMADV method is defined as:
While six sigma has been effective for many companies, there are other manufacturing programs that can help you reduce manufacturing variations and defects. Total Quality Control Total quality control or total quality management (TQM) works toward creating defect-free products by placing an emphasis on management roles. If management is able to lead the company in quality improvement, they will help their staff members find ways to create products that satisfy the needs of the customers. There are 3 main aspects of TQM:
TQM helps companies realize that it is a company-wide approach to reducing defects and eliminating product variations. Mangers will begin to look at the processes within the company and determine if machinery needs to be replaced or if employees need to adopt a new level of performance. Quite often TQM is known as a team effort because it is focused on building relationships within the company to create a healthy working environment. When employees have respect for their coworkers and appreciate their jobs, they are less-likely to have mistakes. The small defects will stop happening and you will save money on production costs. The 5 "S" Methodology Another popular lean manufacturing method is the 5 "S" method. This method is based on 5 Japanese words that begin with the letter `S'. This method helps companies learn how to organize their workspace to make it more productive. One of the first aspects of the 5 S method is to tidy the factory. Each employee needs to have an organized workspace so they can become more efficient with their job responsibilities. The workplace must be arranged after a manner for everyone to understand. This may include using storage bins and other things to help them find the tools they need. The factory must also remain as clean as possible. Having a clean workspace will help employees remain focused because they will not be distracted. Another important part of the 5 S method is to create standardized procedures. This will apply to recycling and other things that can be re-used in the plant. The final piece of the 5 S method is known as progress. All employees will be given time to input their ideas about the method to determine if it is working and if it is reducing defects and product variations.
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