Part 2: Implementing TLS (Theory of Constraints, Lean, and Six Sigma)
I am flying back from teaching a Green Belt course in Las Angeles, California and as promised, I will continue my “journal” of TLS implementation efforts at an industrial organization.
In the last blog, we discussed how this organization was using the metric of “Yield” to score their production process success. We discussed that this metric only shows you what happens at the end of their process, and doesn’t give visibility to the success of the many internal steps. In order to implement TLS, we needed to have a better way to look at our process systemically. We also needed to have a way of determining where our constraints are.
Following the “Lean” methodology, we decided to use O.E.E.(Overall Equipment Effectiveness) as a primary facility metric. We had an overall “Plant” OEE, and we had OEE’s per line and per product. OEE would give us visibility to how we were performing with respect to Performance (Ratio of Daily production to effective capacity), Quality (the number of Good vs. Bad product), and Availability (ratio of used production time to available production time).
We also needed to take data on each of the critical steps in each line to understand where our constraints or bottlenecks were. We defined six critical points that were common to each line (because the lines were almost replicates of each other).
Our plan at the moment is to define each critical point in the lines in a metric and describe throughput (with a common denominator) of each point. We will track the throughput on a continual basis. This will tell us our constraint, and we will set our process TAKT time to the constraint.
We know what our goal TAKT time is … but we cannot set our process TAKT time to produce more than our constraint. Therefore, if our process TAKT time does not meet our goal TAKT time, then we use Lean and Six Sigma tools to cross the chasm. In my next blog, I will talk more about our Implementation progression and about the synergy between the three methodologies that make up TLS (Theory of Constraints, Lean and Six Sigma). I will also give more information on TAKT time to those who have not heard of the concept.
Benefits of Onsite Training:
In the last blog, we discussed how this organization was using the metric of “Yield” to score their production process success. We discussed that this metric only shows you what happens at the end of their process, and doesn’t give visibility to the success of the many internal steps. In order to implement TLS, we needed to have a better way to look at our process systemically. We also needed to have a way of determining where our constraints are.
Following the “Lean” methodology, we decided to use O.E.E.(Overall Equipment Effectiveness) as a primary facility metric. We had an overall “Plant” OEE, and we had OEE’s per line and per product. OEE would give us visibility to how we were performing with respect to Performance (Ratio of Daily production to effective capacity), Quality (the number of Good vs. Bad product), and Availability (ratio of used production time to available production time).
We also needed to take data on each of the critical steps in each line to understand where our constraints or bottlenecks were. We defined six critical points that were common to each line (because the lines were almost replicates of each other).
Our plan at the moment is to define each critical point in the lines in a metric and describe throughput (with a common denominator) of each point. We will track the throughput on a continual basis. This will tell us our constraint, and we will set our process TAKT time to the constraint.
We know what our goal TAKT time is … but we cannot set our process TAKT time to produce more than our constraint. Therefore, if our process TAKT time does not meet our goal TAKT time, then we use Lean and Six Sigma tools to cross the chasm. In my next blog, I will talk more about our Implementation progression and about the synergy between the three methodologies that make up TLS (Theory of Constraints, Lean and Six Sigma). I will also give more information on TAKT time to those who have not heard of the concept.
About Six Sigma Development Solutions, Inc.
We are Certified as an Accredited Training Organization with the International Association of Six Sigma Certification (IASSC)
“The IASSC Accredited Training Organization (ATO) designation validates Six Sigma Development Solutions, Inc. has demonstrated adequate management systems, courseware with a high degree of correlation to the subject matter contained in the IASSC Bodies of Knowledge, delivery schema consistent with such content and highly qualified instructors.”
We Provide Public Lean Six Sigma Lean Six Sigma Green Belt and Lean Six Sigma Black Belt Certification Training Courses in 34 Cities across the globe.
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We Provide Onsite Lean Six Sigma Certification Training. Some of the training's we provide are: Lean Six Sigma Black Belt, Lean Six Sigma Green Belt, Lean Six Sigma Yellow Belt, Lean Six Sigma Champions Training and Lean Certifications for Healthcare, Finance, I.T, Manufacturing, Processing, Logistics, Retail Sales and Government.
SSDSI will come to your site to train for your choice of the Lean Six Sigma Certification Levels. Onsite training is more cost effective than open enrollment training when training larger groups of team members.
Benefits of Onsite Training:
The Training is focused on Your Opportunities
SSDSI uses your opportunities in class (vs. generic examples)
You will get the experience of a seasoned Lean and Six Sigma Master Black Belt who will help mentor you while completing your Lean and Six Sigma Project
You can train up to 20 employees for one fixed cost (this cost includes courseware and the instructors travel & lodging)
Our courses are full of games, simulations, and active learning to help the adult learner
SSDSI can customize the training to meet your company’s particular training needs
For More Information Contact: Kevin Clay, MBB at 866-922-6566 or kclay@sixsigmadsi.com
Six Sigma Certification is another certification that, bit by bit, rises to fame.
ReplyDeleteThis course is very important since business is what runs within an organization.
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