Lean Six Sigma tools

What are the management tools for Lean Six Sigma? Lean Six Sigma (LSS) is a combination of Lean production and Six Sigma management, and the five tools of DOE, MSA, FMEA, SPC, QFD are some of the most commonly used Lean Six Sigma tools.

Lean 6 Sigma is a combination of Lean production and 6 Sigma management, the essence of which is to eliminate waste. Lean 6 Sigma Management aims to absorb the advantages of the two production models by integrating Lean Production with 6 Sigma Management to make up for the shortcomings of a single production model and achieve better management results. Lean 6 Sigma is not a simple combination of lean production and 6 Sigma, but a complementary and organic combination of the two.

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Introduction to the five tools of Lean Six Sigma Management – DOE, MSA, FMEA, SPC, QFD :

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Lean Six Sigma Management Tool 1 – DOE Experimental Design

Design of Experiments, abbreviated as DOE, is a mathematical theory and method for studying how to develop appropriate experimental schemes for effective statistical analysis of experimental data. Experimental design should follow three principles: randomization, local control and repetition. The purpose of randomization is to avoid bias due to the influence of the main objective system. Local control is the partition group, so that the conditions within the group as much as possible consistent; Repetition is intended to reduce the effects of random errors and is still aimed at avoiding the effects of controllable systemic factors. Experimental design can be divided into four types: analysis design, district design, regression design and uniform design. The design is divided into a comprehensive implementation law and a partial implementation law.

Experimental design refers to the knowledge of the general procedure of scientific research, which includes a series of contents from question presentation, hypothesis formation, variable selection and so on to the analysis of results and the writing of papers. DOE can be applied to analyze key factors, optimize results, and improve design fitness as product development, products, and processes improve.

Lean Six Sigma Management Tool 2 – MSA Measurement System Analysis

The measurement system analyzes Measurement System Analysis, which uses mathematical statistics and charting methods to analyze the errors of the measurement system to assess whether the measurement system is appropriate for the parameters being measured, thereby determining the status, direction of improvement and system acceptability of the inspection system.

MSA training can help you in using mathematical statistics and charting methods to analyze the resolution and error of the measurement system to assess whether the resolution and error of the measurement system is appropriate for the parameters being measured, and to determine the main components of the measurement system error.

The error of the measurement system is characterized by the statistical characteristics of multiple measurement data of the measurement system operating under stable conditions: bias and variance. Bias refers to the position of the measurement data relative to standard values, including bias, linearity, and stability of the measurement system; Variance, on the other hand, refers to the degree to which the measurement data is dispersed, also known as the measurement system’s R-R, including the repeatability and reproducibility of the measurement system.

Lean Six Sigma Management Tools 3 – FMEA and FTA Analysis

Failure mode and effect analysis (FMEA) and fault tree analysis (FTA) are analytical techniques that have been widely used in reliability engineering, and have been successfully applied abroad to solve various quality problems. In the ISO 9004:2000 standard, FMEA and FTA analysis have been used as methods of risk assessment for design and development, as well as product and process validation and changes. At present, FMEA and FTA technology are basically applied only to reliability design analysis, according to foreign literature and the practice of some enterprise technicians, FMEA and FTA can be applied to process analysis and quality analysis. Quality is a concept with a wide range of connotations, and reliability is one of them. Through FMEA and FTA analysis, various potential quality problems and failure patterns affecting product quality and reliability and their causes (including design defects, process problems, environmental factors, aging, wear and process errors) were identified, and corrective actions were taken by design and process.

FMEA training: through FMEA training and learning, you can master FMEA tools, that can be reasonably used in product design and process development risk analysis and determine improvement measures; Master the logical relationships and processes of FMEA analysis, expand the output of FMEA into control plans and role guidance, and ensure effective control of risk points in field operations. 　　Be proficient in the features and usage of the new version of FMEA to meet customer needs.

Lean Six Sigma Tool 4 – Statistical Process Control (SPC)

Statistical Process Control, or SPC, was proposed by Dr. Huehart in the United States in the 1920s, and since World War II, SPC has gradually become the basic method of online quality control in Western industrial countries. According to SPC theory, the fluctuation of product quality characteristics is the root cause of quality problems, quality fluctuations have statistical regularity, through the control chart can find anomalies, through the process control and diagnosis theory can find out the cause of abnormalities and eliminate them. The SPC approach is a powerful tool for keeping production lines stable and reducing quality fluctuations.

SPC training: Through typical case study and operation training, your SPC analysis and SPC application ability are quickly improved. Helps you to understand the ideas and basic tools for solving quality problems.

Lean Six Sigma Management Tool 5 – QFD Quality Function Deployment

Quality Function Deployment is a multi-level interpretation and analysis of customer demand for products, into product design requirements, component characteristics, process requirements, production requirements of quality engineering tools, used to guide the robust design and quality assurance of products. This technology originated in Japan, has been further developed in the United States, and has been widely used around the world. Quality Function Deployment is one of the most important methods that must be applied to Six Sigma. In the conceptual design, optimization design and validation phases, quality function expansion can also play an auxiliary role.

QFD Training: QFD training can help you explore how to integrate customer requirements into product design, through examples and the application of many tools, a thorough understanding of customer needs and conversion into technical indicators, through the concept of QFD, detailed design QFD, process design QFD and production control QFD transmission and implementation of customer demand into the enterprise product realization process, and finally delivered to customer satisfaction products.

By implementing Lean 6 Sigma, the organizational process can benefit from:

reduce the variation of business processes, improve the ability and stability of processes, improve the robustness of processes or products;

Reduce the number of work in progress, reduce inventory, reduce costs;

Shorten the production beat, shorten the production preparation time, accurately and quickly understand and respond to customer demand;

improve the layout of facilities, reduce production footprint, effective use of resources;

Improve customer satisfaction and market share.

Lean Six Sigma tools