Six Sigma and Lean

What is Six Sigma?

Six Sigma, originally developed by Motorola in 1981, is a business management strategy that focuses on the improvement of processes through identifying and removing defects and reducing the variation. Using Six Sigma will help an organization to meet financial targets such as an increase in profits, reduction of costs, or other items of importance such as cycle time, delivery, quality, etc. that would be crucial to the customer. Contact us to help reach these goals using Six Sigma. 

Six Sigma Project Methodologies
Six Sigma uses two types of project methologies:

  • DMAIC (define, measure, analyze, improve, control), for existing processes
  • DMADV (define, measure, analyze, design, verify), for creating new product or process design

What do we offer to our Customers?

  • Perform training in theory and concepts
  • Implement and apply theory and concepts, as part of DMAIC/DMADV
  • Perform data and graphical analysis
    • Histograms
    • Pareto Chart
    • Probability
    • Regression Analysis
    • Evaluate Process Flow
      • Process Mapping
      • Supplier Input Process Output Customer (SIPOC)
      • Spaghetti Diagrams
      • Value Stream Map (VSM)
      • Prepare analysis for the following:
        • Process Capability Analysis
        • Measurement System Analysis
            • Gage R&R studies
          • Perform Hypothesis Testing
            • Analysis of Variance (for continuous data)
            • Chi-Square Test (for attribute data)
            • Residuals Analysis
            • Perform Root Cause Analysis
            • Design experiments using DOE (Design of Experiment)
              • Optimal Experimentation
              • Multi-Response Optimization
              • Robust Design
              • Estimate risk of process
                • Failure Mode and Effects Analysis (FMEA)
                • Risk Assessment
                • Problem Solving

                What is Statistical Process Control?
                Statistical Process Control (SPC), introduced by W. Edwards Deming, is the monitoring of a process through control charts to reduce its variation about the mean.  Variation in a process may affect quality of the product, which in turn, leads to issues such as an increase in scrap or a greater likelihood that a problem is passed to the customer.

                L2 Business Consulting can help a company to observe and reduce process variations using SPC.  This would lead to a reduction in cycle time of a product, less rework, identifying and eliminating bottlenecks, and reducing other delays that are related to the process.

                What do we offer to our Customers?

                • Perform training in theory and concepts
                • Implement the use of Control Charts
                • Create or improve Control and Reaction Plans
                • Statistical Modeling

                What is Lean Manufacturing?
                Lean Manufacturing, derived from the Toyota Production System (TPS), is a systematic approach to flow the product at the demand of customer while identifying and eliminating wastes using continuous improvement. In a nutshell, Lean Manufacturing, or just Lean, is about maximizing the customer value while minimizing waste. L2 Business Consulting is able to streamline processes using tools from Lean Manufacturing, eliminating wastes and non-value-added events. In doing so, less waste for more value.

                5S is the foundation of Lean Manufacturing, providing necessary groundwork for workplace improvement. It consists of Sort, Straighten, Shine, Standardize, and Sustain. Having a structured 5S program in the company empowers employees to sustain their work area, which in turn will increase product and process quality and strengthen pride in employee’s work.

                Kaizen events, as part of the whole Lean initiative, are used to rapidly implement work cells, improve setups, streamline processes and implement 5S using a team of people familiar with the area. The event includes training of the team to understand the concept of the event, analysis, design and rearrangement of the product line or area. Depending on the area, the event is normally 2-10 days, with results seen immediately, both dramatic and satisfying.  

                What do we offer to our Customers?

                • Perform training in theory and concepts
                • Facilitate Kaizen Events
                • Analyze and perform Setup Reductions
                  • SMED (Single Minute Exchange of Die)
                • Evaluate and eliminate 7 Wastes
                • Evaluate flow
                  • Non-value added vs. value added events
                  • Just-In-Time
                  • Takt time
                • Develop or improve a 5S System with Visual Controls