Friday, 10 February 2012

    The essential of six-sigma strategy

    There are eight phases involved in applying Six Sigma to achieve world class performance in a process, division or company:
    1. Recognize
    2. Define
    3. Measure
    4. Analyze
    5. Improve
    6. Control
    7. Standardize, and
    8. Integrate.
    Each phase is designed to ensure the methodical and disciplined application of the Strategy, the correct definition and execution of Six Sigma projects, and the incorporation of results in day-to-day business endeavors.

    These eight components of the strategy fall into one of four categories:

    Identification. The Recognize and Define phases fall under this category, in which companies begin to understand the fundamental concepts of Six Sigma and recognize Six Sigma as a problem-solving methodology with a unique set of tools. These phases allow companies to recognize how their processes affect profitability, then define what the critical-to-business processes are. The key component for companies to address in these two phases is variation across processes — how much of an impact variation has on results in terms of cost, cycle time and defect rates.

    Characterization. Measure and Analyze fall into this category, which considers where a process is at the time it is measured and points to the goals to which a company should aspire by establishing baselines and benchmarks — thus providing a starting point for measuring improvements. Leadership creates an action plan to close the gap between current and desired processes, to meet goals for a particular product or service. It entails breaking down every product into its key characteristics, creating a detailed description of every step in a process, and measuring short- and long-term process capabilities.

    Optimization. This category (comprised of the Improve and Control phases) identifies the steps required to improve a process and reduce the major sources of variation. Key process variables are identified through statistically designed experiments, and the “vital few” that have greatest impact are isolated. The knowledge gained from these steps is then used to improve and control a process, ultimately improving profitability, customer satisfaction and shareholder value.

    Institutionalization. The Standardize and Integrate phases that comprise the Institutionalization stage address the integration of Six Sigma into the way a business is managed on a day-to-day basis. More than just a focus of projects through to completion, this stage offers a way to step back and look at how collective results of smaller projects affect the large, high-level processes that run the day-to-day business.

    Of course the difficult part is actually deploying this strategy! How have you implemented a successful continuous improvement strategy?



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    12 Leverage Points: How to Control the System

    The twelve leverage points to intervene in a system were proposed by Donella Meadows, a scientist and system analyst focused on environmental limits to economic growth. The leverage points, first published in 1997, were inspired by her attendance at a North American Free Trade Agreement (NAFTA) meeting in the early 1990s where she realized that a very large new system was being proposed but the mechanisms to manage it were ineffective.

    Meadows, who worked in the field of systems analysis, proposed a scale of places to intervene in a system. Awareness and manipulation of these levers is an aspect of self-organization and can lead to collective intelligence.

    Her observations are often cited in energy economics, green economics and human development theory.

    She started with the observation that there are levers, or places within a complex system (such as a firm, a city, an economy, a living being, an ecosystem, an ecoregion) where a "small shift in one thing can produce big changes in everything" (compare: constraint in the sense of Theory of Constraints).

    She claimed we need to know about these shifts, where they are and how to use them. She said most people know where these points are instinctively, but tend to adjust them in the wrong direction. This understanding would help solve global problems such as unemployment, hunger, economic stagnation, pollution, resources depletion, and conservation issues.

    Meadows started with a 9-point list of such places, and expanded it to a list of twelve leverage points with explanation and examples, for systems in general.

    She describes a system as being in a certain state, and containing a stock, with inflows (amounts coming into the system) and outflows (amounts going out of the system). At a given time, the system is in a certain perceived state. There may also be a goal for the system to be in a certain state. The difference between the current state and the goal is the discrepancy.

    For example, one might consider a lake or reservoir, which contains a certain amount of water. The inflows are the amount of water coming from rivers, rainfall, drainage from nearby soils, and waste water from a local industrial plant. The outflows might be the amount of water used up for irrigation of nearby cornfield, water taken by that local plant to operate as well as the local camping site, water evaporating in the atmosphere, and trickling surplus water when the reservoir is full.
    TRUE 4D Procedural Animation, created by contr...Image via Wikipedia
    Local inhabitants complain about the water level getting low, pollution getting higher, and the potential effect of hot water release in the lake on life (in particular, the fish).
    This is the difference between the perceived state (pollution or low water level) and the goal (a non-polluted lake).

    Leverage points to intervene in a system (in increasing order of effectiveness)

    12. Constants, parameters, numbers (such as subsidies, taxes, standards)

    Parameters are points of lowest leverage effects. Though they are the most clearly perceived among all leverages, they rarely change behaviors and therefore have little long-term effect.

    For example, climate parameters may not be changed easily (the amount of rain, the evapotranspiration rate, the temperature of the water), but they are the ones people think of first (they remember that in their youth, it was certainly raining more). These parameters are indeed very important. But even if changed (improvement of upper river stream to canalize incoming water), they will not change behavior much (the debit will probably not dramatically increase).

    11. The size of buffers and other stabilizing stocks, relative to their flows

    A buffer's ability to stabilize a system is important when the stock amount is much higher than the potential amount of inflows or outflows. In the lake, the water is the buffer: if there's a lot more of it than inflow/outflow, the system stays stable.

    For example, the inhabitants are worried the lake fish might die as a consequence of hot water release directly in the lake without any previous cooling off.
    However, the water in the lake has a large heat capacity, so it's a strong thermic buffer. Provided the release is done at low enough depth, under the thermocline, and the lake volume is big enough, the buffering capacity of the water might prevent any extinction from excess temperature.
    Buffers can improve a system, but they are often physical entities whose size is critical and can't be changed easily.

    10. The structure of material stocks and flows (such as transport network, population age structures)

    A system's structure may have enormous effect on operations, but may be difficult or prohibitively expensive to change. Fluctuations, limitations, and bottlenecks may be easier to address.

    For example, the inhabitants are worried about their lake getting polluted, as the industry releases chemicals pollutants directly in the water without any previous treatment. The system might need the used water to be diverted to a waste water treatment plant, but this requires rebuilding the underground used water system (which could be quite expensive).

    9. The length of delays, relative to the rate of system changes

    Information received too quickly or too late can cause over- or underreaction, even oscillations.

    For example, the city council is considering building the waste water treatment plant. However, the plant will take 5 years to be built, and will last about 30 years. The first delay will prevent the water being cleaned up within the first 5 years, while the second delay will make it impossible to build a plant with exactly the right capacity.

    8. The strength of negative feedback loops, relative to the effect they are trying to correct against

    A negative feedback loop slows down a process, tending to promote stability (stagnation). The loop will keep the stock near the goal, thanks to parameters, accuracy and speed of information feedback, and size of correcting flows.

    For example, one way to avoid the lake getting more and more polluted might be through setting up an additional tax, relative to the amount and the degree of the water released by the industrial plant. The tax might lead the industry to reduce its releases.

    7. The gain around driving positive feedback loops

    A positive feedback loop speeds up a process. Meadows indicates that in most cases, it is preferable to slow down a positive loop, rather than speeding up a negative one.

    The eutrophication of a lake is a typical feedback loop that goes wild. In a eutrophic lake (which means well-nourished), lots of life can be supported (fish included).
    An increase of nutrients will lead to an increase of productivity, growth of phytoplankton first, using up as much nutrients as possible, followed by growth of zooplankton, feeding up on the first ones, and increase of fish populations. The more nutrients available there is, the more productivity is increased. As plankton organisms die, they fall at the bottom of the lake, where their matter is degraded by decomposers.
    However, this degradation uses up available oxygen, and in the presence of huge amounts of organic matter to degrade, the medium progressively becomes anoxic (there is no more oxygen available). Upon time, all oxygen-dependent life dies, and the lake becomes a smelly anoxic place where no life can be supported (in particular no fish).

    6. The structure of information flow (who does and does not have access to what kinds of information)

    Information flow is neither a parameter, nor a reinforcing or slowing loop, but a loop that delivers new information. It is cheaper and easier than changing structure.

    For example, a monthly public report of water pollution level, especially nearby the industrial release, could have a lot of effect on people's opinions regarding the industry, and lead to changes in the waste water level of pollution.

    5. The rules of the system (such as incentives, punishment, constraints)

    Pay attention to rules, and to who makes them.

    For example, a strengthening of the law related to chemicals release limits, or an increase of the tax amount for any water containing a given pollutant, will have a very strong effect on the lake water quality.

    4. The power to add, change, evolve, or self-organize system structure

    Self-organization describes a system's ability to change itself by creating new structures, adding new negative and positive feedback loops, promoting new information flows, or making new rules.

    For example, microorganisms have the ability to not only change to fit their new polluted environment, but also to undergo an evolution that make them able to biodegrade or bioaccumulate chemical pollutants. This capacity of part of the system to participate to its own eco-evolution is a major leverage for change

    3. The goal of the system

    Changes every item listed above: parameters, feedback loops, information and self-organisation.

    A city council decision might be to change the goal of the lake from making it a free facility for public and private global use, to a more touristic oriented facility or a conservation area. That goal change will effect several of the above leverages : information on water quality will become mandatory and legal punishments will be set for any illegal polluted effluent.

    2. The mindset or paradigm that the system — its goals, structure, rules, delays, parameters — arises out of

    A society paradigm is an idea, an unstated assumption that everyone shares, thoughts, or states of thoughts that are sources of systems. Paradigms are very hard to change, but there are no limits to paradigm change. Meadows indicates paradigms might be changed by repeatedly and consistently pointing out anomalies and failures to those with open minds.

    A current paradigm is "Nature is a stock of resources to be converted to human purpose". What might happen to the lake were this collective idea changed ?

    1. The power to transcend paradigms

    Transcending paradigms may go beyond challenging fundamental assumptions, into the realm of changing the values and priorities that lead to the assumptions, and being able to choose among value sets at will.

    Many today see Nature as a stock of resources to be converted to human purpose. Many Native Americans see Nature as a living god, to be loved, worshipped, and lived with. These views are incompatible, but perhaps another viewpoint could incorporate them both, along with others.

    Global Barriers to Lean Understanding

    We all know that lean and six sigma cuts waste and boosts productivity but an essential "tool" which is often overlooked in these projects is effective communication. And no where is it required more if project teams don't speak English as a first language.

    Generally, if we want a successful outcome when you're crossing international boundaries:
    good quality means that the target audience received the message its provider intended it to receive.
    This communication issue manifests itself in global sourcing. However, even though: you should obtain parts locally, as close to your plant as possible, to eliminate the waste of transportation firms are increasingly:
    • exploiting global efficiencies in production
    • identifying alternate supplier sources
    • utilizing buffer capacities and
    • taking advantage of specific geographical talent pools.
    China dominates the global sourcing directions of most firms, particularly for those based in the United States and Europe. However, near-shore sourcing destinations such as South America and Eastern Europe form significant second-tier markets.

    Indeed, research has shown that a low-cost country sourcing can have a positive impact on company performance in terms of cost and quality although the time dimension remains to be a challenge.

    An illustration of a company's supply chainImage via WikipediaSo, whether or not a local or global supply base makes sense is really up to the company, customer and market sector involved. I believe there should be as a minimum three supply base goals:
    1. quality improvement to Six Sigma levels
    2. delivery performance measured zero days late, to one day early
    3. total cost of ownership improvement.
    Also you don't want improvements to come at the expense of supplier margins. The supply base needs to make reasonable margins in order to remain healthy, commercially viable suppliers. Supply chain management is meant to reduce excess inventory in the supply chain. A supply chain should be demand driven. It is built on the pull approach of customers pulling inventory, not with suppliers pushing inventory. Excess inventory reflects the additional time with the supply chain operation. So the perfect supply chain would be lean with removing wasteful time and inventory regardless of where it is in the world.

    What do you think? Can a global supply chain be lean?
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