Lean, 6-sigma for green Manufacturing Competence
Keywords:
Make in India, System of systems, DOWNTIME (Seven Wastes), Synergy, Thareja’s AUM modelAbstract
There is a serious intent of the present government to invigourate manufacturing, which cannot happen unless the industry caters to customer’s requirements fully, sincerely, and competitively. But to make this ambition live the industry must gear up with the use of tools, policies and paradigms, such that the various issues are brought under control. Some of these higher level tools/ paradigms include the use of Lean Manufacturing / Green Manufacturing and Six Sigma.
This paper attempts to evaluate the characteristics of two tools/ paradigms of Lean for Green manufacturing, and Six Sigma, discussing their boundaries, impacts on application, and constraints/ limitations of their operational area.
We attempt to build up a case for their deployment in an integrated form, and if and how they could be combined to fulfill the objects of the customer and the three objectives of waste reduction, defect reduction, and an environment which is green and motivating for the operators. The objective is contemplated to further energise the Make in India initiative of government of India.
How to cite this article: Thareja M. Lean, 6-sigma for green Manufacturing Competence. J Adv Res Qual Control Mgmt 2018; 3(1&2): 25-36.
References
1. Pyzdek T. The six sigma. McGrow-Hill, New York. 2003.
2. P Thareja. A Total Quality Organization Thru’ People (Part 21: Lean People, Mean People, Green People), FOUNDRY, An Indian Journal For Progressive Metal Casters 2009; 21(2(123)): 41-48.|url= https://papers. ssrn.com/sol3/papers.cfm?abstract_id=1633896
3. (N.A) Mattel Recalls 19 Million Toys Sent From China, https://www.nytimes.com/2007/08/15/business/ worldbusiness/15imports.html
4. Rankin J, Toyota recalls more than 6.5m cars over steering and seat problems, The Guardian, Wed 9 Apr 2014 https://www.theguardian.com/business/2014/ apr/09/toyota-recalls-over-6m-cars-worldwide
5. Robert E. Cole, What Really Happened to Toyota?, sloan review, Magazine: June 22, 2011, https://sloanreview. mit.edu/article/what-really-happened-to-toyota/ 6. (n.a)The Guardian https://www.theguardian.com/ business/2010/jan/29/timeline-toyota-recallaccelerator-pedal
7. Robert Boothand David Teather, Faulty pedals and millions of cars recalled: Toyota’s reputation accelerates into trouble The Guardian Tue 2 Feb 2010 21.09 GMT, https://www.theguardian.com/business/2010/feb/02/ faulty-cars-recalled-toyota-reputation
8. Patrice Novotny Toyota Recalls 1.5 Million Cars Over Brake Fluid Leak, Oct 21, 2010, https://www. industryweek.com/companies-amp-executives/toyotarecalls-15-million-cars-over-brake-fluid-leak
9. Why Toyota Is Recalling 5.8 Million Cars Worldwide REUTERS, October 26, 2016, http://fortune.com/2016/ 10/26/toyota-recall-takata-airbag-cars/
10. Jennifer Rankin, Toyota recalls more than 6.5m cars over steering and seat problems, The Guardian, Wed 9 Apr 2014 https://www.theguardian.com/business/2014/ apr/09/toyota-recalls-over-6m-cars-worldwide
11. Thareja P. SHEQ To Shake The Car Development For Tomorrow: Part II (Infrastructural Shortfall And Growth @ Future-Cars), Trends In Mechanical Engineering & Technology, 2016; 6(1): 79-95.
12. Eisenstein PA. Dark Clouds Gather Over Toyota After New Safety Setback,” Oct. 21, 2010, and http://msnbc. com; and “Nissan Recalls 2 Million Cars Worldwide,” Oct. 27, 2010, http://msnbc.com
13. Thareja P. Holean Human Leadership - Developing from First Principles (December 24, 2011). IBA Journal of Management & Leadership 2011; 3(1): 59- 70. Available at SSRN: https://ssrn.com/abstract=2116262 or http:// dx.doi.org/10.2139/ssrn.2116262
14. Conner G. Six sigma and other continuous improvement tools for the small shop. Dearborn, MI: The Society of Manufacturing Engineers 2002.
15. Andersson R, Eriksson H, Torstensson H. Similarities and differences between TQM, six sigma and lean. The TQM magazine. 2006; 18(3):282-96.
16. McCurry L, McIvor, RT. Agile manufacturing: 21st century strategy for manufacturing on the periphery?”, Conference Proceedings, Irish Academy of Management Conference, University of Ulster, September 2001.
17. Earley T, http://leanmanufacturingtools.org/71/mudamura-and-muri-lean-manufacturing-wastes/
18. https://www.biz-pi.com/product/tim-wood-leanwastes-slides/
19. NIST, Principles of Lean Manufacturing with Live Simulation, Manufacturing Extension Partnership, National Institute of Standards and Technology, Gaithersburg, MD 2000.
20. Thareja P, Sharma A, Leaning Pizza, Journal of Production Research & Management 2011; 1(1): 1-18.
21. Wyrwicka M, Mrugalska B. Barriers to eliminating waste in production system. Proceedings of the 6th international conference on engineering, project, and production management; 2015: 354–363.
22. Hines R, Holweg M, Rich N. Learning to evolve: a review of contemporary lean thinking. Int. J. Oper. Prod. Manag. 2004; 24(10): 994-1011.
23. EPA. Lean Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment and Recommendations for Leveraging Better Environmental Performance. 2003. http://www. epa.gov/lean/environment/pdf/leanreport.pdf
24. Bicheno J, Holweg M. The Lean Toolbox, 5th edition. A handbook for lean transformation. January 2016, Edition: 5th, PICSIE Books
25. Becky MorganWhy lean fails so often | Association for Manufacturing Excellence Apr 22, 2016. https://www. ame.org/target/articles/2016/why-lean-fails-so-often
26. Melton T. The Benefits Of Lean Manufacturing-What Lean Thinking Has To Offer The Process Industries Chemical Engineering Research and Design 83(A6): 662–673.
27. Dove R. Knowledge management, response ability and the agile enterprise. Journal of Knowledge Management 1999; 3(1): 18-35.
28. Cusumano M A. The limits of lean. Sloan Management Review 1994; 35(4): 27-32.
29. Devane T. Integrating Lean Six Sigma and High Performance Organizations, Pfeiffer/ A Wiley Imprint, San Francisco, CA 2004.
30. Kang, Chiweon : The Synergy Effect Between Six Sigma And Lean Manufacturing. Management Technology University Of Wisconsin –Stout, 2005.
31. Breyfogel FW, Clupello JM, Meadows B. Managing Six Sigma. New York: Wiley-Interscience 2001.
32. Thareja M, Thareja P. Holistic Management of Process Thru 4-DM Methodology. Journal of Education in Engineering and Technology 2008 2(2). Available at SSRN: https://ssrn.com/abstract=1487591 or http:// dx.doi.org/10.2139/ssrn.1487591
33. Thareja P. Competitive Foundry Through Integration of TIPS (Technology, Innovation, Product Design and Process Systems), (Key note talk at BRICS Foundry Forum, Brazil) [also in Indian Foundry Journal 2012; 58(1)].
34. Munk J. How Six Sigma Helps Eliminate the 8 Wastes, APRIL 15, 2015, https://www.sixsigmadaily.com/8wastes/
35. Thareja P, Kaushik SK. Vsm In Aid Of Lean Production In Automotive Industry-A Case Study’ Proceedings of the 8th International Conference on Manufacturing Research ICMR 2010- Advances in Manufacturing Technology XXIV (Ed Professor V I Vitanov and Prof D Harrison), UK, 16th Sept 2010.
36. Trojacek D. The Synergy of Lean and Six Sigma https:// www.linkedin.com/pulse/synergy-lean-six-sigma-dantrojacek
37. Vinodh S, Arvind KR, Somanaathan M. Tools and techniques for enabling sustainability through lean initiatives. Clean Technologies and Environmental Policy 2010; 13(3): 469-479.
38. Andrea P, Found P, Bernardes AM. A Lean and Green Model for a production cell. Journal of cleaner production 2014; 85: 19 -30.
39. Bergmiller G, McCright P. Are Lean and Green Programs Synergistic. Proceedings of the 2009 Industrial Engineering Research Conference, Miami, FL, USA 2009. 40. Garza-Reyes JA. Lean and Green e a systematic review of the state of the art literature. J Clean Prod 2015; 102: 18-29.
41. Carvalho H, Duarte S, Cruz-Machado V. Lean, agile, resilient and green: divergences and synergies. International Journal of Lean Six Sigma 2011; 2(2): 151-179. 42. Mollenkopf D et.al. Journal of Physical Distribution & Logistics Management 2010; 40(1&2): 14-41.
43. Klefsjo ? B, Wiklund H, Edgeman R. Six Sigma seen as a methodology for total quality management. Measuring Business Excellence 2001; 5(1): 31-5.
44. Six Sigma quality: A structured review and implications for future research. Available from: https://www. researchgate.net/publication/238193459_Six_Sigma_ quality_A_structured_review_and_implications_for_ future_research
45. Thareja P, Thareja M. Relevance of Statistics and Learning Perception of Engineering students. Research & Reviews: Journal of Statistics 2012; 1(2): 34-51.
46. Thareja P. Chasing Competence – A Journey through Metamorphosis Using Six Sigma. Journal of Advanced Research in Production and Industrial Engineering 2014; 1(1): 1-11.
47. Chaneski W. Lean and Six Sigma: Synergy at Work’, Modern machine SHOP, 2016. https://www.mmsonline. com/columns/lean-and-six-sigma-synergy-at-work 48. Thareja P. A Total Quality Organization Thro’ People: (Part 25). People as a System of Systems, Foundry, An Indian Journal For Progressive Metal Casters, Vol xxii, No 1, Jan / Feb. 2010
49. Robert E. Cole Who Was Really at Fault for the Toyota Recalls? MAY 1, 2011, https://www.theatlantic.com/ business/archive/2011/05/who-was-really-at-faultfor-the-toyota-recalls/238076/
50. Salah S, Rahim A, Carretero JA. The integration of Six Sigma and Lean Management. International Journal of Lean Six Sigma 2010; 1(3): 249-274.
51. Pepper and Spedding. The evolution of lean Six Sigma. International Journal of Quality and Reliability Management 2010; 27(2): 138-155.
52. Arnheiter and Maleyeff. The integration of lean management and Six Sigma, The TQM Magazine 2005; 17(1): 5-18.
53. Galeazzo A, Furlan A, Vinelli A. Lean and green in action: interdependencies and performance of pollution prevention projects. Journal of Cleaner Production 85: 191-200.
54. George ML. Lean Six Sigma Combining Six Sigma Quality with Lean Speed” quoted in George, M., Rowlands, D. and Kastle, B. What is Lean Six Sigma?, McGraw-Hill Companies, New York, NY 2003.
55. De Koning H, De Mast J, Does RJMM. Generic Lean Six Sigma project Definitions in Financial Services. Quality Management Journal 2008; 15(4): 32-45.
56. Roy A, Henrik Eriksson, Håkan Torstensson. Similarities and differences between TQM, six sigma and lean, The TQM Magazine, 2006 18(3): 282-296.
57. Bendell T. A review and comparison of Six Sigma and the lean organizations, The TQM Magazine 2006; 18(3): 255-262
58. Snee RD. Lean Six Sigma – getting better all the time, International Journal of Lean Six Sigma 2010; 1(1): 9-29.
59. Thareja P. A Total Quality Organization Thro’ People: (Part 19) ‘Spring A Spanner In The Sprocket’, Foundry, An Indian Journal For Progressive Metal Casters, 2009; 21(1): 81-87.
60. Lakhe RR, Mohanty RP. Total Quality Management Concepts, Evolution and Acceptability in Developing Economies, International Journal of Quality & Reliability Management 1994; 11(9): 9-33.
61. Kluczek A. Quick Green Scan: A Methodology for Improving Green Performance in Terms of Manufacturing Processes, Sustainability 2017; 9: 88.
62. Thareja P, Sharma DD, Mahapatra PB. Total Quality Management - A Developmental Perspective. Journal of Production Research & Management 2011; 1(1): 38-56.
2. P Thareja. A Total Quality Organization Thru’ People (Part 21: Lean People, Mean People, Green People), FOUNDRY, An Indian Journal For Progressive Metal Casters 2009; 21(2(123)): 41-48.|url= https://papers. ssrn.com/sol3/papers.cfm?abstract_id=1633896
3. (N.A) Mattel Recalls 19 Million Toys Sent From China, https://www.nytimes.com/2007/08/15/business/ worldbusiness/15imports.html
4. Rankin J, Toyota recalls more than 6.5m cars over steering and seat problems, The Guardian, Wed 9 Apr 2014 https://www.theguardian.com/business/2014/ apr/09/toyota-recalls-over-6m-cars-worldwide
5. Robert E. Cole, What Really Happened to Toyota?, sloan review, Magazine: June 22, 2011, https://sloanreview. mit.edu/article/what-really-happened-to-toyota/ 6. (n.a)The Guardian https://www.theguardian.com/ business/2010/jan/29/timeline-toyota-recallaccelerator-pedal
7. Robert Boothand David Teather, Faulty pedals and millions of cars recalled: Toyota’s reputation accelerates into trouble The Guardian Tue 2 Feb 2010 21.09 GMT, https://www.theguardian.com/business/2010/feb/02/ faulty-cars-recalled-toyota-reputation
8. Patrice Novotny Toyota Recalls 1.5 Million Cars Over Brake Fluid Leak, Oct 21, 2010, https://www. industryweek.com/companies-amp-executives/toyotarecalls-15-million-cars-over-brake-fluid-leak
9. Why Toyota Is Recalling 5.8 Million Cars Worldwide REUTERS, October 26, 2016, http://fortune.com/2016/ 10/26/toyota-recall-takata-airbag-cars/
10. Jennifer Rankin, Toyota recalls more than 6.5m cars over steering and seat problems, The Guardian, Wed 9 Apr 2014 https://www.theguardian.com/business/2014/ apr/09/toyota-recalls-over-6m-cars-worldwide
11. Thareja P. SHEQ To Shake The Car Development For Tomorrow: Part II (Infrastructural Shortfall And Growth @ Future-Cars), Trends In Mechanical Engineering & Technology, 2016; 6(1): 79-95.
12. Eisenstein PA. Dark Clouds Gather Over Toyota After New Safety Setback,” Oct. 21, 2010, and http://msnbc. com; and “Nissan Recalls 2 Million Cars Worldwide,” Oct. 27, 2010, http://msnbc.com
13. Thareja P. Holean Human Leadership - Developing from First Principles (December 24, 2011). IBA Journal of Management & Leadership 2011; 3(1): 59- 70. Available at SSRN: https://ssrn.com/abstract=2116262 or http:// dx.doi.org/10.2139/ssrn.2116262
14. Conner G. Six sigma and other continuous improvement tools for the small shop. Dearborn, MI: The Society of Manufacturing Engineers 2002.
15. Andersson R, Eriksson H, Torstensson H. Similarities and differences between TQM, six sigma and lean. The TQM magazine. 2006; 18(3):282-96.
16. McCurry L, McIvor, RT. Agile manufacturing: 21st century strategy for manufacturing on the periphery?”, Conference Proceedings, Irish Academy of Management Conference, University of Ulster, September 2001.
17. Earley T, http://leanmanufacturingtools.org/71/mudamura-and-muri-lean-manufacturing-wastes/
18. https://www.biz-pi.com/product/tim-wood-leanwastes-slides/
19. NIST, Principles of Lean Manufacturing with Live Simulation, Manufacturing Extension Partnership, National Institute of Standards and Technology, Gaithersburg, MD 2000.
20. Thareja P, Sharma A, Leaning Pizza, Journal of Production Research & Management 2011; 1(1): 1-18.
21. Wyrwicka M, Mrugalska B. Barriers to eliminating waste in production system. Proceedings of the 6th international conference on engineering, project, and production management; 2015: 354–363.
22. Hines R, Holweg M, Rich N. Learning to evolve: a review of contemporary lean thinking. Int. J. Oper. Prod. Manag. 2004; 24(10): 994-1011.
23. EPA. Lean Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment and Recommendations for Leveraging Better Environmental Performance. 2003. http://www. epa.gov/lean/environment/pdf/leanreport.pdf
24. Bicheno J, Holweg M. The Lean Toolbox, 5th edition. A handbook for lean transformation. January 2016, Edition: 5th, PICSIE Books
25. Becky MorganWhy lean fails so often | Association for Manufacturing Excellence Apr 22, 2016. https://www. ame.org/target/articles/2016/why-lean-fails-so-often
26. Melton T. The Benefits Of Lean Manufacturing-What Lean Thinking Has To Offer The Process Industries Chemical Engineering Research and Design 83(A6): 662–673.
27. Dove R. Knowledge management, response ability and the agile enterprise. Journal of Knowledge Management 1999; 3(1): 18-35.
28. Cusumano M A. The limits of lean. Sloan Management Review 1994; 35(4): 27-32.
29. Devane T. Integrating Lean Six Sigma and High Performance Organizations, Pfeiffer/ A Wiley Imprint, San Francisco, CA 2004.
30. Kang, Chiweon : The Synergy Effect Between Six Sigma And Lean Manufacturing. Management Technology University Of Wisconsin –Stout, 2005.
31. Breyfogel FW, Clupello JM, Meadows B. Managing Six Sigma. New York: Wiley-Interscience 2001.
32. Thareja M, Thareja P. Holistic Management of Process Thru 4-DM Methodology. Journal of Education in Engineering and Technology 2008 2(2). Available at SSRN: https://ssrn.com/abstract=1487591 or http:// dx.doi.org/10.2139/ssrn.1487591
33. Thareja P. Competitive Foundry Through Integration of TIPS (Technology, Innovation, Product Design and Process Systems), (Key note talk at BRICS Foundry Forum, Brazil) [also in Indian Foundry Journal 2012; 58(1)].
34. Munk J. How Six Sigma Helps Eliminate the 8 Wastes, APRIL 15, 2015, https://www.sixsigmadaily.com/8wastes/
35. Thareja P, Kaushik SK. Vsm In Aid Of Lean Production In Automotive Industry-A Case Study’ Proceedings of the 8th International Conference on Manufacturing Research ICMR 2010- Advances in Manufacturing Technology XXIV (Ed Professor V I Vitanov and Prof D Harrison), UK, 16th Sept 2010.
36. Trojacek D. The Synergy of Lean and Six Sigma https:// www.linkedin.com/pulse/synergy-lean-six-sigma-dantrojacek
37. Vinodh S, Arvind KR, Somanaathan M. Tools and techniques for enabling sustainability through lean initiatives. Clean Technologies and Environmental Policy 2010; 13(3): 469-479.
38. Andrea P, Found P, Bernardes AM. A Lean and Green Model for a production cell. Journal of cleaner production 2014; 85: 19 -30.
39. Bergmiller G, McCright P. Are Lean and Green Programs Synergistic. Proceedings of the 2009 Industrial Engineering Research Conference, Miami, FL, USA 2009. 40. Garza-Reyes JA. Lean and Green e a systematic review of the state of the art literature. J Clean Prod 2015; 102: 18-29.
41. Carvalho H, Duarte S, Cruz-Machado V. Lean, agile, resilient and green: divergences and synergies. International Journal of Lean Six Sigma 2011; 2(2): 151-179. 42. Mollenkopf D et.al. Journal of Physical Distribution & Logistics Management 2010; 40(1&2): 14-41.
43. Klefsjo ? B, Wiklund H, Edgeman R. Six Sigma seen as a methodology for total quality management. Measuring Business Excellence 2001; 5(1): 31-5.
44. Six Sigma quality: A structured review and implications for future research. Available from: https://www. researchgate.net/publication/238193459_Six_Sigma_ quality_A_structured_review_and_implications_for_ future_research
45. Thareja P, Thareja M. Relevance of Statistics and Learning Perception of Engineering students. Research & Reviews: Journal of Statistics 2012; 1(2): 34-51.
46. Thareja P. Chasing Competence – A Journey through Metamorphosis Using Six Sigma. Journal of Advanced Research in Production and Industrial Engineering 2014; 1(1): 1-11.
47. Chaneski W. Lean and Six Sigma: Synergy at Work’, Modern machine SHOP, 2016. https://www.mmsonline. com/columns/lean-and-six-sigma-synergy-at-work 48. Thareja P. A Total Quality Organization Thro’ People: (Part 25). People as a System of Systems, Foundry, An Indian Journal For Progressive Metal Casters, Vol xxii, No 1, Jan / Feb. 2010
49. Robert E. Cole Who Was Really at Fault for the Toyota Recalls? MAY 1, 2011, https://www.theatlantic.com/ business/archive/2011/05/who-was-really-at-faultfor-the-toyota-recalls/238076/
50. Salah S, Rahim A, Carretero JA. The integration of Six Sigma and Lean Management. International Journal of Lean Six Sigma 2010; 1(3): 249-274.
51. Pepper and Spedding. The evolution of lean Six Sigma. International Journal of Quality and Reliability Management 2010; 27(2): 138-155.
52. Arnheiter and Maleyeff. The integration of lean management and Six Sigma, The TQM Magazine 2005; 17(1): 5-18.
53. Galeazzo A, Furlan A, Vinelli A. Lean and green in action: interdependencies and performance of pollution prevention projects. Journal of Cleaner Production 85: 191-200.
54. George ML. Lean Six Sigma Combining Six Sigma Quality with Lean Speed” quoted in George, M., Rowlands, D. and Kastle, B. What is Lean Six Sigma?, McGraw-Hill Companies, New York, NY 2003.
55. De Koning H, De Mast J, Does RJMM. Generic Lean Six Sigma project Definitions in Financial Services. Quality Management Journal 2008; 15(4): 32-45.
56. Roy A, Henrik Eriksson, Håkan Torstensson. Similarities and differences between TQM, six sigma and lean, The TQM Magazine, 2006 18(3): 282-296.
57. Bendell T. A review and comparison of Six Sigma and the lean organizations, The TQM Magazine 2006; 18(3): 255-262
58. Snee RD. Lean Six Sigma – getting better all the time, International Journal of Lean Six Sigma 2010; 1(1): 9-29.
59. Thareja P. A Total Quality Organization Thro’ People: (Part 19) ‘Spring A Spanner In The Sprocket’, Foundry, An Indian Journal For Progressive Metal Casters, 2009; 21(1): 81-87.
60. Lakhe RR, Mohanty RP. Total Quality Management Concepts, Evolution and Acceptability in Developing Economies, International Journal of Quality & Reliability Management 1994; 11(9): 9-33.
61. Kluczek A. Quick Green Scan: A Methodology for Improving Green Performance in Terms of Manufacturing Processes, Sustainability 2017; 9: 88.
62. Thareja P, Sharma DD, Mahapatra PB. Total Quality Management - A Developmental Perspective. Journal of Production Research & Management 2011; 1(1): 38-56.
Published
2018-06-05
How to Cite
Thareja, M. (2018). Lean, 6-sigma for green Manufacturing Competence. Journal of Advanced Research in Quality Control & Management, 3(1&2), 25-36. Retrieved from https://adrjournalshouse.com/index.php/Journal-QualityControl-Mgt/article/view/727
Issue
Section
Research Article
Copyright (c) 2018 Journal of Advanced Research in Quality Control & Management
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
