Elimination of Industrial waste by Lean Six Sigma

 

Can you think about an organization without incurring any unnecessary waste?

No, Right? There is some waste in the workplace in a different form- may it be time, techniques, employees, etc.

In the same way, process owners are struggling day and night for preventing wastage from the production process to reaching it to end-users. Even, in countless companies, it is getting affected without their knowledge and further hampering the output, sales process with incurring losses.

When 3m’s Environmental, Health, Safety Operations (EH&SO) The organization adopted Lean Six Sigma in 2000-2005 of aiming to improve corporate ESH service and activities focusing on operational efficiency, product yielding, direct reduction in energy use, waste reduction, air emissions.  The EH&SO organization had two belts( Black Belt and Master Black Belt) under the Lean Six Sigma training program for their in-house employees.  The members of EHS undergone green belt training and thereby black belt training. 

Lean Six Sigma has become a powerful engine for expanding the support system where the “voice of customers” results reflected the increase in the performance. As the LSS activities increased at 3M, much of the waste and variation targeted in the outcome of the project has brought the changes in their coattails.

In the year 2005, 3M has enhanced efficiency by reducing air emission by 25%, use of energy efficiency by 20%, reduce waste by 20%, and implementation of 800 3P projects.  This has proved to be the strongest result for all types of firms that are holding companies for construction, manufacturing, or any industrial services.

Waste and Lean Six Sigma

Six Sigma leaders define waste as an action in a process that does not add value for the customer and thereby steps need to be taken for the elimination of the waste and maximizing the project potentials. Under these circumstances, a tool is required to serve the purpose and the wastage problem. Under this situation, Lean Six Sigma has become an anticipated tool to consider and strategies to solve the managerial defects of the organization. Today many companies are implementing LSS to identify and eliminate wastage.

Here are the few types of waste that can be eliminated and the solution by implementing Lean Six Sigma:

Motion

What do we think if we see a person is running out that means he is busy, according to our view busyness is productivity, Right..?

No, not really... Do not fall into the trap, in fact, employees physically move further than required, and unnecessary workforces are enabled them to spend more time on that. 

Solution: Lean six sigma helps to identify whether the motion is being added to the waste list. Once identified, the waste can be eliminated by reorganizing the filing and inventory system, redesigning the workplace layout so that it becomes easier for the worker to work and get all the tools, materials from the workstation. These will become more productive without any wastage.

Unused employee talent

Recruiting the best talent could be a waste if it is not utilized properly, even the workers working in the process has the best idea about improving them. But, hardly the management allows the employees to contribute to the system by ideating or giving them the responsibility of the project.

In most cases, the management gives the guideline of a project and asks the team to follow. These do not bring much job satisfaction, productivity, and devotion to the work.

Solution: Lean Six Sigma can help the organization by removing the wastage of employee unused talents and maximizing them. Employee Engagement can be a great way of adding additional value to the employees and train them if required, and eventually involving them in the project and decision making in the organization. 

Waiting

This might sound harmless, but be careful of the waste. It is caused to a loss in the capital. There are situations when we wait for raw material, equipment, and information required for the product or services. No one likes to pay the employee for sitting ideal in the organization and the wasted time is nothing but a wastage of money. Therefore, it needs to be fixed for the long run of the organization.

Solution: LSS helps in identifying the defective areas and redesigning them by managing a swift flow of work and eliminated the waiting wastage and delivered the required materials in time. So that the workers take up the work one after the other.

Transportation 

The ability to move through a succession of people from one place to another can all incur waste, i.e. who all do not add value to the transformation process of raw materials for which the customers are willing to pay. Movement may look fruitful or productive but it has not involved the customer’s benefit and rather it is a waste of resources.

Solution: Lean Six Sigma can manage the issue by removing the waste may it be time or money. Redesigning the process by creating and analyzing the process map with an eye for eliminating unneeded movement or changing the route if needed may add value.

As soon as the defect is detected, by using Lean Six Sigma tools and techniques it can be eliminated. It is an ongoing evolving process and the wastage can be reduced to achieve the desired goal. The companies can enjoy a more organized work culture once the waste has been eliminated.

To know more about Six Sigma write to in-fmsixsigma@kpmg.com or reach at +91 – 998 774 4776, +91 – 999 975 5655 or +91 – 997 245 8726

Author- Puja Das