May 28 2015
Why Your Lean and Six Sigma Improvement Efforts Aren’t Driving Better Results | IndustryWeek | John Dyer
“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).”
Source: www.industryweek.com
Jul 31 2017
Acceptance Sampling In The Age Of Low PPM Defectives
Today, some automotive parts manufacturers are able to deliver one million consecutive units without a single defective, and pondering quality management practices appropriate for this level of performance is not idle speculation. Of course, it is only achieved by outstanding suppliers using mature processes in mature industries.
You cannot expect it during new product introduction or in high-technology industries where, if your processes are mature, your products are obsolete. While still taught as part of the quality curriculum, acceptance sampling has been criticized by authors like W. E. Deming and is not part of the Lean approach to quality.
For qualified items from suppliers you trust, you accept shipments with no inspection; for new items or suppliers you do not trust, you inspect 100% of incoming units until the situation improves. Let us examine both what the math tells us about this and possible management actions, with the help of 21st century IT.
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By Michel Baudin • Laws of nature • 5 • Tags: Acceptance Sampling, DPMO, Lean Quality, Six Sigma, SPC