Operational Excellence is traditionally linked to Lean and Six Sigma techniques. we took the essence of
these techniques and specifically designed for our MSME customers. It starts with organizational
assessment during which a current assessment and scope is realized. Typical Operational Excellence
Journey for any Organization is shown as per below.

 

1. 5S

The 5S Methodology is a system for organizing spaces so work can be performed efficiently & effectively without compromising Safety. 
5S Stands for 

• 1S – Seiri – Sort
• 2S – Seiton – Set in Order
• 3S – Seiso – Shine
• 4S – Seiketsu – Standardize
• 5S – Shitsuke – Sustain

Benefits of 5S Methodology 

• Increase Productivity Through Effectiveness
• Reduction in Delays
• Improved Quality
• Improvement in Safety 
• Morale and Motivation increase
• Reduction in setup times

2. Kaizen

Kaizen is a process from Japanese manufacturing technology and means consistent innovation
management or simply improvement!

KAI = Change & ZEN = for the better

KAIZEN in the workplace means continuous improvement in which all are involved
Kaizen philosophy is for improvement by everyone, anytime, anywhere.

Principles of Kaizen

• Improve Everything continuously
• Abolish Old and Traditional Concepts
• See Problems as Opportunities
• Correct the mistakes
• Empower everyone to take part in problem solving
• Be transparent
• Take opinion from multiple people
• KYC (Know Your Customer)
• Know that improvement has no limits
• Be Economical

3. Lean

Lean management is focussed on process speed and quality through reduction of process wastes.

There are typically 8 main wastes happening in any organization:

1. Defects – Efforts caused by rework, scrap, and incorrect information 
2. Over-Production – Producing ahead of or in anticipation of demand
3. Waiting – Production delays, waiting for supplies, materials, or manpower to complete
4. Non-utilized skills – wasted or unused resources, skills, Knowledge
5. Transportation – Unnecessary movement of products or materials
6. Inventory - Holding above the strategic amount of stock, raw materials or WIP
7. Motion – Excessive movement of people or equipment to perform the intended task
8. Extra-Processing – Unnecessary steps to process parts or satisfy customer needs

Principles of Kaizen

1. Define Value
2. Map the Value Stream
3. Create Flow
4. Establish Pull system
5. Pursuit Perfection

There are over 50 lean tools available that organizations can adopt for lean management. Lean tools can be selected based on the characteristics of organization and services provided. 

Six Sigma (6σ)

Six Sigma (6σ) philosophy focuses on Customer CTQ (Critical to Quality) criteria. This can help achieve breakthrough improvements. Six Sigma (6σ) DMAIC Key steps are as per below: -

1. Define
2. Measure
3. Analyse
4. Improve
5. Control

Statistical tools are applied to arrive at potential significant improvements. 

 

5. DFSS (Design for Six Sigma)

Design for Six Sigma (DFSS) is a product development approach that complements the Six Sigma problem-solving methodology. The major objective of Design for Six Sigma is to “design it right the first time” to avoid painful downstream experiences. The term “Six Sigma” in the context of Design for Six Sigma can be defined as the level at which design vulnerabilities are not effective or minimal. There are no universal roadmap like DMAIC for DFSS. 

There are 11 different roadmaps followed for Design for Six Sigma (DFSS).

Design for Six Sigma (DFSS) is a product development approach that complements the Six Sigma problem-solving methodology. The major objective of Design for Six Sigma is to “design it right the first time” to avoid painful downstream experiences. The term “Six Sigma” in the context of Design for Six Sigma can be defined as the level at which design vulnerabilities are not effective or minimal. There are no universal roadmap like DMAIC for DFSS. 

There are 11 different roadmaps followed for Design for Six Sigma (DFSS).

1. DMADV: Define, Measure, Analyse, Design, Verify
2. IDDOV: Identify, Define, Develop, Optimize, And Verify.
3. DCOV: Define, Characterize, Optimize, Verify
4. IDOV: Identify, Design, Optimize, Validate
5. DCCDI: Define, Customer, Concept, Design, Implementation
6. DMEDI: Define, Measure, Explore, Develop, Implement
7. DMADOV: Define, Measure, Analyse, Design, Optimize, Verify
8. ICOV: Identify Requirement, Characterize, Optimize, Verify
9. CDOV: Concept Development, Design Development, Optimization, Verify Certification
10. IIDOV: Invent, Innovate, Develop, Optimize, Verify
11. IDEAS: Identity, Design, Evaluate, Assure, Scale-Up

Despite these naming differences, all versions of Design for Six Sigma share fundamental strategies and tools that promote a common goal: “to create a data-driven product development culture that efficiently produces winning products”(Soderborg 2004). Thus, the Design for Six Sigma methodology is still a straightforward, four or five-step process, just like Six Sigma’s DMAIC.

As you may notice from above, the tools and methodology are typical to apply as each organization is different and their problems are unique in terms of their business. Through our extensive assessment methodology, we arrive at current state of your organization, and design your Operational Excellence Journey which also includes balanced scorecard tools, employee engagement practices, reporting and monitoring through KPIs (Key Performance Indicators) and OKRs (Objectives and Key Results) and many more. 

We handhold and co-design together with your team the required actions, resources and structure necessary to evolve the current execution practice. We also make sure there is buy in from both the management team and the main stakeholders to succeed in its implementation. During this process your team is cultured to follow continuous improvement – keystone of any successful and progressive organization. 

Let’s build the culture of Continuous Improvement and Grow Together!!