Did you know, one of the aerospace parts manufactures was able to reduce its process time by 46% after implementing six sigma processes?

An aerospace parts manufacturer wanted to lower the cost of manufacturing of his products. The managerial team of this organization decided to implement Six Sigma processes to improve and reduce the cycle time of the machine. This process of reducing the cycle time would help to decrease the cost of manufacturing.

Few members of the organization were given the trained so that they can further train other teams in the organization. This implementation team was named as Six Sigma team. The six sigma team members helped other teams to accelerate the process. This team comprised of members from management and machine operators.

The six-sigma team executed the six-sigma process. During the first phase, when the cycle time was measured, it was at 1200 seconds. The Six Sigma team wanted to reduce the cycle time by 50%. For that, the sigma level was set at a minimum level of three.

The team also discovered quite a few risk factors including reduction of overtime, faster business pace and less time for inspection. For the team to understand the current state of the company’s process, a process map was made along with an implementation plan.

During the second phase, key metrics were identified. The data that was prior collected was analyzed later to check the stability during this phase. Statistical data analysis was performed to identify the reasons for the long cycle time. The data also discovered areas of improvement. In some cases, up to 40% improvement was identified. 

During the third phase, solutions were formulated, and lean concepts were used to create potential solutions. Several solutions were identified and presented to the management team and were ranked in terms of their credibility to solve the problem. The solutions were put into the primary stage. After the process was measured, the solutions were proven to be stable and had a Sigma value of more than five. This led to a 20% reduction in cycle time.

During the last phase, a new process map and training plans were created and executed. Possible issues were found in the environment, human factors and methods. To handle the risks, control plans were created and put into place. After executing the Six Sigma principles, there was a 46% improvement in the cycle time and an 80% reduction in variation.

Six Sigma implementation has been delivering phenomenal results. Similar results can be delivered to your organization as well. Have you started implementing six sigma principles yet?