Reducing the delivery lead time in a food distribution SME through the implementation of six sigma methodology

Purpose – Six sigma is a systematic data driven approach to reduce the defect and improve the quality in any type of business. The purpose of this paper is to present the findings from the application of six sigma in a food service “small to medium sized enterprise” (SME) in a lean environment to reduce the waste in this field. Design/methodology/approach – A simplified version of six sigma is adopted through the application of appropriate statistical tools in order to focus on customer's requirements to identify the defect, the cause of the defect and improve the delivery process by implementing the optimum solution. Findings – The result suggests that modification in layout utilization reduced the number of causes of defect by 40 percent resulting in jumping from 1.44 sigma level to 2.09 Sigma level which is substantial improvement in SME. Research limitations/implications – Simplicity of six sigma is important to enabling any SME to identify the problem and minimize its cause through a systematic approach. Practical implications – Integrating of supply chain objectives with any quality initiatives such as lean and six sigma has a substantial effect on achieving to the targets. Originality/value – This paper represents a potential area in which six sigma methodology along side the lean management can promote supply chain management objectives for a food distribution SME

Approaches to Managing Complexity in Project Production

Since the seminal contribution by Shewhart, the dominating approach to production is to minimize all variation in order to get the productive activities into control. Thus, the goal is to avoid all such complexity and uncertainty which could disturb this tight control. This approach is applied in lean production,which is considered to be the superior production template of today.It has to be noted that usually our concepts, for example “waste”, are based on this understanding of production. However, there are production situations with inherent complexity and unpredictability not least in project production. The primary goal of the paper is to chart and analyze the different approaches available for coping with these situations. Four different strategies are identified and discussed: reducing complexity, codifying procedures, learning to improvise and buffering. A secondary goal of the paper is to discuss whether and how the conceptual framework in production management should be further developed for taking these different approaches to project complexity into account

Framework for continuous improvement of production processes

This research introduces a new approach of using Six Sigma DMAIC (Define, Measure, Analyse, Improve, Control) methodology. This approach integrates various tools and methods into a single framework, which consists of five steps. In the Define step, problems and main Key Performance Indicators (KPIs) are identified. In the Measure step, the modified Failure Classifier (FC), i.e. DOE-NE-STD-1004-92 is applied, which enables to specify the types of failures for each operation during the production process. Also, Failure Mode and Effect Analysis (FMEA) is used to measure the weight of failures by calculating the Risk Priority Number (RPN) value. In order to indicate the quality level of process/product the Process/Product Sigma Performance Level (PSPL) is calculated based on the FMEA results. Using the RPN values from FMEA the variability of process by failures, operations and work centres are observed. In addition, costs of the components are calculated, which enable to measure the impact of failures on the final product cost. A new method of analysis is introduced, in which various charts created in the Measure step are compared. Analysis step facilitates the subsequent Improve and Control steps, where appropriate changes in the manufacturing process are implemented and sustained. The objective of the new framework is to perform continuous improvement of production processes in the way that enables engineers to discover the critical problems that have financial impact on the final product. This framework provides new ways of monitoring and eliminating failures for production processes continuous improvement, by focusing on the KPIs important for business success. In this paper, the background and the key concepts of Six Sigma are described and the proposed Six Sigma DMAIC framework is explained. The implementation of this framework is verified by computational experiment followed by conclusion section

Do we need one science of production in healthcare?

The question addressed is: Is there need, in health care, for one consolidated science of production? For responding to this question, the classical science of production is reviewed and the current approaches to production and service in healthcare are analysed as for their evolution and current status. It is found that these current movements are not self-aware of the restrictions deriving from their backgrounds, and of the resultant partiality in their approaches. It is concluded that improvement of healthcare is slowed down by the fragmentation of the related disciplines; thus one consolidated science of production (of healthcare) is needed

Towards an Operational Definition of Lean Construction Onsite

Through literature review and drawing from a combined professional experience of over 20 years of lean construction implementation, this paper investigates the key success factor for the automotive industry’s uptake of lean production to see what the construction industry can derive from it. The paper concludes that there exist a variety of definitions of lean, but no existing definition is yet satisfactory to describe lean construction in a rigorously testable method. This is a major obstacle to the successful deployment of lean construction especially when the industry does not have a standard benchmark of “what a lean site looks like”. It recommends a small-scale replication of the International Motor Vehicle Programme (IMVP) led International Automotive Plant Study (IAPS) in construction. This will be in aid of developing an operational definition of lean construction, in line with Deming’s understanding, in the form of a lean site assessment tool contributing to a Lean Index. A statistical study is also suggested to establish correlation between the degrees of lean application (Lean Index) and project performanc

Target value design: using collaboration and a lean approach to reduce construction cost

Target Costing is an effective management technique that has been used in manufacturing for decades to achieve cost predictability during new products development. Adoption of this technique promises benefits for the construction industry as it struggles to raise the number of successful outcomes and certainty of project delivery in terms of cost, quality and time. Target Value Design is a management approach that takes the best features of Target Costing and adapts them to the peculiarities of construction. In this paper the concept of Target Value Design is introduced based on the results of action research carried out on 12 construction projects in the USA. It has been shown that systemic application of Target Value Design leads to significant improvement of project performance – the final cost of projects was on average 15% less than market cost. The construction industry already has approaches that have similarities with elements of the Target Value Design process or uses the same terminology, e.g. Partnering and Target Cost Contracts, Cost planning, etc. Following an exploration of the similarities and differences Target Value Design is positioned as a form of Target Costing for construction that offers a more reliable route to successful projects outcomes

Facilitators and barriers to the integration of healthcare service and building design

Service design research recognises the importance of infrastructure design in the achievement of streamlined service delivery. Although research about service design and building design is abundant, very little is known about the integration of these processes. Therefore, this research aimed at identifying facilitators and barriers to the integration of service and building design processes. To this end, the initial results from a historical investigation of the redevelopment of a hospital in Salford, UK were used to identify facilitators and barriers to the integration of service and building design. Data was collected through interviews, document analysis and a workshop. Initial results present internal and external factors related to the design process generating barriers to integration of service and building design

The 8th flow - common understanding

Projects are a form of engineered-to-order (ETO) production which require that the definition of Value becomes part of the production process. Project production requires the inclusion of the product design, the design process, and the production process to be integrated in order to fully benefit from waste reduction and process improvement. In construction, project production is more challenging because of the temporal, transient, and fragmented nature of the project team and the supporting supply chain. This requires a form of ‘interoperability’ between the supply chain organisations, the particular teams involved, the commissioning clients and other stakeholders. It is proposed that this ‘interoperability’ is a form of common understanding and that this understanding needs to be defined, developed, and nurtured across the project execution as a flow in the same way that other flows are managed. Building on the seven flow model proposal reported by Koskela and Howell (1999), this paper proposes a common understanding as an eighth flow and suggests how it might be managed. The paper classifies the concept of common understanding as a soft flow and shows that although it is a fresh insight it actually has roots in lean production. The identity of common understanding as the eighth flow arises from a number of funded research projects in which the difficulties of lean construction implementation were investigated