What are the most successful Lean manufacturing and Six Sigma programs in the manufacturing industry?

2 Motorola Six Sigma

Motorola Six Sigma is the pioneer and benchmark of Six Sigma, a data-driven approach to reducing variation and defects in processes. It was developed in the 1980s by Motorola engineers, who wanted to improve the reliability and performance of their products. Six Sigma uses a structured methodology called DMAIC (Define, Measure, Analyze, Improve, Control) to identify and eliminate the root causes of problems, and achieve a defect rate of less than 3.4 per million opportunities. Motorola Six Sigma has helped the company save billions of dollars, win the prestigious Malcolm Baldrige National Quality Award, and become a leader in telecommunications and electronics.

3 GE Work-Out

GE Work-Out is a hybrid program that combines elements of Lean manufacturing and Six Sigma, as well as other tools and techniques. It was launched in the 1990s by GE CEO Jack Welch, who wanted to transform the company's culture and performance. Work-Out is based on three main components: speed, simplicity, and self-confidence. Speed means making decisions and implementing changes faster, by eliminating bureaucracy and empowering employees. Simplicity means simplifying processes and products, by eliminating waste and complexity. Self-confidence means trusting employees and customers, by encouraging feedback and collaboration. GE Work-Out has helped the company achieve significant improvements in quality, efficiency, innovation, and profitability.

4 Boeing Lean+

Boeing Lean+ is a comprehensive program that applies Lean principles and practices to all aspects of the company's operations, from design and engineering, to manufacturing and delivery, to customer service and support. It was initiated in the 2000s by Boeing CEO Alan Mulally, who wanted to increase the company's competitiveness and responsiveness in the aerospace industry. Lean+ focuses on four key areas: value stream mapping, flow production, pull system, and continuous improvement. Value stream mapping means identifying and eliminating waste and non-value-added activities in the entire value chain. Flow production means optimizing the layout and sequence of processes, to reduce cycle time and inventory. Pull system means producing based on customer demand, to avoid overproduction and waiting. Continuous improvement means constantly seeking and implementing better ways of doing things, to enhance quality and efficiency. Boeing Lean+ has helped the company reduce costs, increase productivity, and deliver more value to customers.

5 Honeywell Operating System

The Honeywell Operating System (HOS) is a holistic program that integrates Lean manufacturing, Six Sigma, and other best practices, to create a culture of excellence and performance. It was developed in the 2000s by Honeywell CEO Dave Cote, who wanted to align the company's diverse businesses and functions around a common vision and strategy. HOS is based on five pillars: safety, quality, delivery, inventory, and productivity. Safety means ensuring the health and well-being of employees, customers, and communities. Quality means meeting or exceeding customer expectations, by preventing and eliminating defects. Delivery means delivering products and services on time, in full, and at the right place. Inventory means optimizing the amount and flow of materials, to reduce waste and working capital. Productivity means maximizing the output and value of resources, to reduce costs and increase profits. HOS has helped Honeywell improve its operational performance, customer satisfaction, and growth.

6 Here’s what else to consider

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