“Don’t expect a positive ROI from your lean and Six Sigma investments if they are nothing but a pretty picture.
I once had a plant manager tell me his factory had implemented Six Sigma, but there was not a single statistical process control chart. How is that possible? Another had the control charts in place but refused to allow the operator to shut the process down when it indicated an out-of-control condition. Another plant claimed it was lean but had a dozen bins of parts stacked on the floor as part of a two bin system. Another plant routinely violated the daily production plan by rescheduling orders, and then the plant blamed the supply chain for causing it to frequently run out of parts (which then drove it to change the schedule… a vicious circle).”