Content area
Full Text
Abstract
The Six Sigma methodology (with the five phases defined by DMAIC) is used in manufacturing and transactional processes in order to reduce variation. Lean Manufacturing is a methodology used to reduce cycle time and to minimize waste. In order to improve the efficiency of DMAIC some changes are recommended. Particularly, in the Measurement phase the use of Lean techniques may reduce the elaboration time of the variable identification. This paper presents a modified Value Stream Mapping tool (Lean tool) as a substitute for the Process Flow Diagram and the Detailed Map. This modified VSM includes elements that allow an easier analysis and evaluation of the selected process and a graphical perspective. Thus detection of critical variables and opportunity improvement areas are achievable in less time and less effort.
Key Words
Value Stream Mapping, Six Sigma, Process Flow Diagram, opportunity improvement.
1. Introduction
Most organizations, no matter what they produce, make mistakes that have a cost, could be a lost customer, time or wasted material, a part that has to be replaced, the loss of efficiency, the need to do a certain task over again, and other things. Six Sigma was developed for minimizing those mistakes and maximizing value for their customers. It is defined as a rigorous, focused, and highly effective implementation of proven quality principles and techniques in any project [1].
The Six Sigma methodology uses the DMAIC model, which involves five phases: define the goals of the improvement activity, measure the existing system, analyze the system to identify ways to eliminate the gap between the current performance of the system or process and the desired goal, improve the system and control the new system. The measurement phase is very important and critical for the project because it allows the establishment of baseline data to later evaluate the impact of the project [2]. This phase begins with a Process Flow Diagram (PFD) to recognize and separate the add-value and non-add-value activities, then to do a Detailed Map that includes some relevant information and can construct a Cause & Effect Matrix, obtaining a set of input variables which are essential for improvement; it is also important to do the Measurement System Analysis (MSA) to determine if the instrument and the process that the...