As Lean Six Sigma concepts continue to deepen into the domestic enterprise production process management, successful cases are also endless. Wire harness processing enterprises using Lean Six Sigma management concepts are also constantly developing and reforming, expecting the Lean Six Sigma concepts and management methods to update the traditional wire harness production process and management, to find more effective optimization programs to improve product quality and production efficiency, reduce costs, make products more competitive advantage in the marketplace; at the strategic level expects to Lean Six Sigma concepts for At the strategic level, the Lean Six Sigma concept is expected to revolutionize the mindset of employees, which not only requires system innovation at the strategic level, but also requires a better mode of business operation, so that the enterprise can develop in a healthy and sustainable way.
I. Overview of Lean Six Sigma Management
Lean thinking originated from the production management style of Toyota in Japan, and the goal of Lean production is to reduce waste, lower costs and realize value-added profits through continuous improvement. Six Sigma is usually the focus of attention of the enterprise quality control personnel, through the use of statistical process control, experimental data monitoring, quality management tools to control the production process and continuous improvement of the process, effectively reduce the defective rate, to achieve zero defect process design. Six Sigma is based on continuous improvement of products and processes and design strategies, the use of rigorous scientific tools and management methods to help enterprises to promote the implementation of business process optimization, aimed at continuous improvement of enterprise production and business processes, to achieve customer satisfaction management methods.
Six Sigma improvement method is to define the existing process (define), measurement (measure), analysis (analyze), improvement (improve), control (control), five phases, also known as DMAIC process redesign, mainly to eliminate defects in the process, so as to improve quality, reduce costs, shorten the cycle of operation, to achieve customer satisfaction. The five phases of DMAIC include:
D (Definition Phase) - to determine the key needs of the customer, identify the aspects of the existing process that need to be improved, and initially formulate a project plan;
M (Measurement Phase) - to measure the old or current process (each process activity) according to the key needs of the customer. M (Measurement Phase) - Measurement (individual process activities or action times) and evaluation of the current process based on the customer's key requirements;
A (Analysis Phase) - Collection of measurement data and related process analysis to identify sources of variation and key factors affecting quality;
I (Improvement Phase) - Finding and establishing the best optimized process with respect to the key factors. I (Improvement Phase) - Find and establish the best optimized process solution with respect to the key factors;
C (Control Phase) - Establish standardized processes, implement and monitor new processes, validate measurement activities, summarize the results of the implementation, raise new issues, and make the whole process fully effective.
The main core of Lean is the embodiment of the concept of value as a starting point, the existing processes related to the elimination of all waste, reduce costs, shorten the process cycle, and enhance the ability to respond quickly to the wiring harness products for the production of small batches of multiple varieties, the requirements of flexible production, in line with the current customer demand. Six Sigma is mainly to eliminate variation in the process, optimize the process, improve product quality, reduce defects, and increase value. In order to enhance efficiency and improve quality to meet customer demand, more and more managers are focusing on the integration of Six Sigma quality management and Lean manufacturing management to form a Lean Six Sigma management model. Lean and Six Sigma both emphasize continuous improvement based on customer satisfaction in their core concepts. The goals of the two are consistent, the use of analytical tools is complementary, and the management model is even more complementary to each other. The combination of the two forms the Lean Six Sigma concept, which not only can significantly improve product quality and increase customer value through Six Sigma management, but also can utilize Lean methods to reduce up-front capital investment and improve efficiency and market responsiveness.
Second, the formation of lean six sigma concept in the production of wire harness
domestic wire harness production started relatively late, but the development is very fast, with the upgrading of consumer electronics technology, automation equipment, the Chinese market has now become the global wiring harness industry growth potential stock, the domestic private wiring harness supply manufacturers have been part of the realization of the scale of some of the part is still in the continuous exploration, and foreign advanced technology and management are still a big gap. There is still a big gap between them and the advanced technology and management style of foreign countries. As Lean Six Sigma management continues to penetrate into the domestic small and medium-sized processing enterprises, many enterprises have tasted the sweetness, the effect is remarkable, production efficiency and management level has been fully improved. In the past ten years, domestic wire processing enterprises have also been Lean Six Sigma management concepts applied to production management and processes in the making, part of the improvement effect is obvious in the wire processing enterprises on their production processes and management has also launched a study. Under the influence of the Lean Six Sigma concept strategy, the management of the product processing plant for the production efficiency and quality of production has an important impact. The cost-effectiveness of the products, the quick response of the internal management process, especially in terms of price and after-sales service, have already had a large market advantage. But some aspects are still deficient in the need for continuous improvement, in order to gradually improve the domestic wiring harness processing quality management, to achieve maximum customer satisfaction.
Third, the implementation of lean six sigma management advantages
Lean production is the starting point for customer demand, to meet customer demand, eliminate all waste, so as to provide customers with the perfect value; Six Sigma management tools to review all operational activities in the product production process, improve quality, optimize the process. Wire harness processing enterprises, the nature of the product diversification, most of the products for the multi-species, small batch and customized products, through the balance and coordination between the production unit to quickly shorten the process cycle and waiting cycle, improve production efficiency, enhance responsiveness. Six Sigma emphasizes a systematic approach to data-based solutions, using its quality analysis tools to show problems at a glance, and through a series of charts, production line supervisors can make continuous improvements through the PDCA method. According to the company's business strategy, following the DMAIC methodology, the company's strategy will be carried out into specific implementation activities, in pursuit of efficiency while taking into account the quality of the product. The implementation of Lean Six Sigma is comprehensively oriented to customer satisfaction, elimination of waste, cost reduction, optimization of processes, continuous improvement, change of ideas and concepts, improvement of the overall quality of the enterprise, create value for the enterprise, win the interests of the enterprise, so that the enterprise can grow sustainably.
Fourth, the implementation of Lean Six Sigma management problems and solutions to explore
Of course Lean Six Two Sigma management in the implementation process will also encounter a variety of problems, its impact on the final results of the implementation, restricting the implementation of the implementation of the progress of the carry out, individuals summarize the use of Lean Six Sigma management of some of the problems that occur and give their own personal solutions to the problem of the proposal.
(1) Lack of attention. In the establishment of the Lean Six Sigma management program, the implementation of several months did not play a significant effect, the old problem is not only not solved but also the emergence of new problems. Often the first project implementation failure, it is difficult to have confidence in the implementation of the latter. Here we are worth noting that not all companies to implement Lean Six Sigma can be successful, the implementation of Lean Six Sigma management program success or not, first of all, senior leadership to pay attention to the establishment of the program to set up a project team to senior leadership, mainly from within the enterprise to select the backbone of the team members, clear implementation of the purpose of Lean. In the implementation of specific projects, according to specific projects, select the appropriate team of grass-roots personnel, through training, the development of a good implementation program in advance, the departments must do a good job of communication, exchange and mutual exchange of experience, learning from each other, and make progress together, otherwise it will be on paper, difficult to implement. At the same time, we need to set up a demonstration production line, the performance of the demonstration production line needs to be shared with other employees of the company, the need for grass-roots employees to participate in the improvement of the demonstration production line for the achievements of the employees need to carry out a certain degree of incentives.
(2) Lack of awareness of lean cost management. Employees do not know enough about the concept of lean management, resulting in lean cost management awareness of the enterprise is weak, if employees do not have a high awareness of lean cost management, the enterprise cost management measures can not be effectively implemented. Some domestic wire processing enterprises are mostly based on the different needs of customers to produce small quantities, diversified products, due to the managers of lean cost awareness is weak, especially the first-line operation of the staff in the production of waste of materials, work is not standardized and other issues of the phenomenon. In view of such phenomena, usually companies can only always have a variety of raw materials, resulting in increased costs, inventory waste phenomenon is serious. Like the wire harness type of production enterprises involved in the production of a large number of links, more need to improve the lean production and cost management awareness. Therefore, Lean emphasizes the participation of all employees, and the concept of Lean production should be implemented to every employee. Effective control of product costs from the source of wire harness materials, wire materials and transportation control, plug products source supplier control. In accordance with the target cost management methods to determine the product cost, to facilitate the later production links to cost control. Specific to the product production process is the need to further adopt lean production methods, the use of six sigma DMAIC steps to optimize its product production process, the non-value-added operations to reduce, improve the efficiency of product production, so that cost management is more convenient. Through the improvement of these specific environments, to provide a lean production environment for the production of products, so that the staff's awareness of lean production in the specific work has been continuously improved.
(3) Mechanical imitation. In terms of improving efficiency and cost reduction, the specifications of each harness demand is not the same, the order quantity is small and the requirements of simple products, the use of mechanized assembly line production, resulting in wasteful consumption of resources; order quantity is large and the product complexity, strict requirements of the product instead of manual operation, resulting in equipment idle phenomenon, these irrational arrangements, invariably make the cost increase. Attention to improve the proportion of automated production and machinery manufacturing, rather than in the labor force production model of simple rotation replacement, regardless of which management model has a scientific theory and practice, can learn from, can not mechanically imitate, need to be based on the actual situation of the enterprise itself. Simple products and small orders can be arranged for manual operation to reduce costs. Complex and strict requirements of the product can be arranged to make molds and related tooling, staff training, mastering multi-functional technology, so that they can adapt to multiple workstations, reduce redundant workstations, reduce labor costs.
(4) the lack of professional Six Sigma analysis tools. At present, many enterprises just listen to others to explain or train the teacher for a short period of training, the staff did not really master the six sigma analysis skills lead to a lot of projects there is no way to find the focus of the direction of the improvement, resulting in the implementation of the six sigma effect is not obvious, the need to establish a complete implementation of the six sigma approach or the use of a number of reasonable tools such as the need to choose the brainstorming method to collect the first problem points, and then use the Plato's diagram to analyze the focus of the problem, and then use the fishbone diagram to analyze the causes of defects. Use the ANOVA in MINITAB to analyze the effect of verification before and after improvement, use DQE to find out the key factors, and use the statistical method of SPC to count the stability of the process. Use the CP method to standardize the relevant information.
(5) Lack of basic training in Lean. At present, many enterprises in the process of implementing the implementation of the implementation of the results are not obvious, because there is no systematic basis for the implementation of the lean effect is not obvious. For example, there is no full participation in quality, no full participation in TPM input, no quick mold change mechanism, waste has not been well eliminated, resulting in the implementation of the effect is not obvious, so for all employees or the need to carry out repeated training for the implementation of the core staff for external training, each month to carry out the appropriate assessment of the spirit of Lean deep plowing into each department and each link, so that the implementation of the smooth results. In order to make the implementation of smooth results.
(6) Lean Six Sigma implementation obstacles. According to Lean Six Sigma management focuses on the participation of all staff, when the process is improved, and the development of standard processes, employees are required to carry out standardized operations. Often some employees are not willing to accept the improvement, they are already used to operate in the old process under the old system; in particular, some old employees with lazy behavior are not easy to accept the new process operation, the standard working hours are reduced after the improvement, and the waiting time for incoming materials is reduced. Specific improvement measures: training and communication to the operating staff, the establishment of a bonus incentive system, eliminating stubborn, recalcitrant employees, promote outstanding activists as a pioneer to improve the project by promoting the implementation of the project team members to improve; aimed at continuous improvement of the project, the smooth implementation of standardized operations, reduce waste, improve efficiency.
(7) Lack of corporate culture establishment. Wire harness type processing enterprises more front-line operators, often only do a single operation process, only care about their own operation process, while not having product quality awareness. Leaders do not pay enough attention to the enterprise culture system, loose system, lack of performance management system. Leaders, as advocates of promoting Six Sigma management, need to establish and cultivate employees' awareness of the pursuit of continuous quality improvement. Emphasis on pay and get mutual balance, the establishment of incentives. After the successful implementation of the Six Sigma improvement project, the corresponding project members need to be given some incentives to motivate everyone to actively pursue the implementation of Six Sigma improvement activities. At the same time, all members should be encouraged to participate in the use of incentives and constraints on the work of good performance, to achieve the goal of controlling the cost of the staff to reward the work of waste of resources, inefficiency of the staff and the department for the corresponding punishment.
V. Conclusion
This paper introduces the basic concepts of Lean Six Sigma management concepts, further elaborates on the implementation steps and purposes of Lean and Six Sigma, and emphasizes the complementary, scientific and efficient nature of the two. Lean management and Six Sigma management in the core concepts are focused on continuous improvement based on customer satisfaction. Briefly describe the current harness processing enterprises to implement the advantages of lean six sigma management style, focusing on the harness processing enterprises to use lean six sigma management on the production process problems and their personal problem solving insights. Wire harness processing enterprises must combine their own characteristics, the effective use of Lean Six Sigma management and tools, in order to effectively improve production efficiency, reduce the production process of all kinds of waste, contribute to the profitability of the enterprise to continue to improve, and contribute to the overall level of management of the enterprise to continue to improve, and effectively enhance the long-term development of the enterprise.