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How can Lean Six Sigma help you improve manufacturing lead times and on-time delivery?

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If you are a manufacturer, you know how important it is to deliver your products on time and meet customer expectations. However, you may also face challenges such as long lead times, high inventory levels, low quality, and frequent defects. How can you overcome these issues and optimize your manufacturing processes? One possible solution is to apply Lean Six Sigma, a methodology that combines the principles of lean manufacturing and Six Sigma to eliminate waste and variation, and improve efficiency and effectiveness. In this article, we will explain what Lean Six Sigma is, how it can help you reduce lead times and improve on-time delivery, and what are some best practices and pitfalls to avoid.

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1 What is Lean Six Sigma?

Lean Six Sigma is a systematic approach to improving manufacturing processes by identifying and eliminating sources of waste and variation that affect quality, speed, and cost. Waste refers to any activity or resource that does not add value to the customer, such as overproduction, waiting, transportation, inventory, motion, overprocessing, and defects. Variation refers to any deviation from the standard or desired output, such as errors, defects, rework, scrap, or customer complaints. Lean Six Sigma uses a set of tools and techniques to measure, analyze, improve, and control processes, and to ensure that they are aligned with customer requirements and business goals.

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Carlo Rojo

Country Lead at GSD Africa | Strategic Advisor | Transformational Leader | P&L Management | Operations Excellence
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Lean Six Sigma is a combination of two powerful manufacturing and operations management strategies. Lean helps eliminate or reduce waste, while Six Sigma helps reduce excessive variation in results from the same inputs. In my experience, if you cannot achieve both simultaneously, it is better to work to lessen variation first. Having less variation in your processes helps greatly in preparing the field for re-aiming your processes closer to the desired result (which is the aim of Lean).

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2 How can Lean Six Sigma reduce lead times?

Lead time is the total time it takes to complete a process or deliver a product, from the moment the customer places an order to the moment they receive it. Reducing lead time is essential for increasing customer satisfaction, minimizing inventory costs, and gaining a competitive edge. Lean Six Sigma can help you reduce lead time by streamlining your value stream, implementing pull systems, and applying 5S. For example, value stream mapping, process flow charts, and spaghetti diagrams can identify and eliminate non-value-added steps. Additionally, kanban cards, visual signals, or electronic systems can trigger production or delivery based on customer demand. Finally, checklists, labels, color codes, or shadow boards can sort, set in order, shine, standardize, and sustain your work area to reduce waste and delays.

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Carlo Rojo

Country Lead at GSD Africa | Strategic Advisor | Transformational Leader | P&L Management | Operations Excellence
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In my experience, it is key to have a strong core team or small group of leaders that understand and embrace the technologies embodied in Lean Six Sigma. Aiming for higher levels of automation, to reduce human factors and error, can be the long-term objective. However in a less than ideal semi- or non-automated environment, it is possible to achieve substantial results through methods as simple as 5S, and ensuring employee training is standardized and thorough enough to achieve the desired results. Reducing human error through the elimination or reduction of visual distractions is one example of a "low-tech" solution, supported by carefully-chosen and helpful visual aids to guide execution teams in preventing, or at least detecting, errors.

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3 How can Lean Six Sigma improve on-time delivery?

On-time delivery is an essential factor for building customer loyalty, reputation, and profitability. Lean Six Sigma can help improve on-time delivery by establishing customer-centric metrics to identify and prioritize customer needs and expectations, applying statistical process control to track and analyze process outputs, and implementing continuous improvement to identify and solve problems. Tools such as voice of the customer, critical to quality, control charts, histograms, Pareto charts, plan-do-check-act, kaizen, and root cause analysis can be used to measure and achieve goals, detect and correct deviations or problems, implement changes, monitor results, and standardize best practices.

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4 What are some best practices and pitfalls of Lean Six Sigma?

Lean Six Sigma is a powerful and proven methodology that can help you improve your manufacturing lead times and on-time delivery, but it also requires careful planning, execution, and evaluation. To ensure success, it is important to align your Lean Six Sigma projects with strategic objectives and customer needs, involve and empower stakeholders, use data and facts to support decisions, and communicate progress transparently. Additionally, Lean Six Sigma should not be used as a one-size-fits-all solution or quick-fix. It is important to consider the long-term impacts and sustainability of efforts, prioritize and manage projects effectively, and foster a culture of collaboration and learning.

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Carlo Rojo

Country Lead at GSD Africa | Strategic Advisor | Transformational Leader | P&L Management | Operations Excellence
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Business is dynamic and ever-changing: products mature and are replaced by successors, processes evolve and mature to the next level, customer expectations spiral upwards, regulations change. I think it is vital to recognize this in initiating, developing, and sustaining a Lean Six Sigma program. What I find most powerful is the integration of the desire to be best-in-class and consistently meet and exceed customer expectations, with company culture, rewards and recognition mechanisms, and employee training and leadership development programs.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can Lean Six Sigma help you improve manufacturing lead times and on-time delivery?

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2

3

4

5

1 What is Lean Six Sigma?

2 How can Lean Six Sigma reduce lead times?

3 How can Lean Six Sigma improve on-time delivery?

4 What are some best practices and pitfalls of Lean Six Sigma?

5 Here’s what else to consider

Lean Manufacturing

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How can Lean Six Sigma help you improve manufacturing lead times and on-time delivery?

1

2

3

4

5

1 What is Lean Six Sigma?

2 How can Lean Six Sigma reduce lead times?

3 How can Lean Six Sigma improve on-time delivery?

4 What are some best practices and pitfalls of Lean Six Sigma?

5 Here’s what else to consider

Lean Manufacturing

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