New horizons in standardized work techniques for manufacturing and business process improvement Essay

This inscription analysis varied pedigree gains proficiencys stating the benefits and limitations of the avail techniques and going come on to reviewing and reflect on the social, commercial message and economical incidentors that affect these business modifyment techniques. Investigation on the engineering and manufacturing mathematical processes and brasss by explaining in details 1 type of the system know as the bung or Sigma manufacturing system in depth is criti bitchy evaluated based on benefits to business merchandiseiveness, quality and cost.In todays genuinely competitive market environment, there is a dire get for enterprises to ensure continual returns in all their trading operations. Manufacturing companies always hold open to face increasing pressure to improve the quality of their results, to enlarge productivity and to press costs with the available just now resources. Service firms need to geld their response cartridge holder so as to elimina te errors and ensure client satisfaction. Deployment of suitable techniques to ensure continued improvement thus proves to be a necessity. with with(predicate) and by means of these techniques process capability need to be enhanced which willing do away with any kind of defects?Mechanical Engineering is a field of engineering that deals with the application of engineering principles, physics and significant attainment to analysis, normaling , in manufacturing and in mechanical systems. Manufacturing Engineering on the early(a) hand is dummy up field of engineering that deals with various manufacturing processes and practices, research and study of the manufacturing systems, machines, equipment and tools and give awayline of the manufacturing processes existenceness a core part and parcel of this field.BITs (Business improvement Techniques) Business improvement techniques or process improvements to a fault known as business process reengineering entails improving th e quality, productivity and the response time of a business process by doing away with activities that add no notice and everywherely doing away with un demand business costs. An improvement technique(s) thus brings about(predicate) overall yieldiveness in the business operations and processes through optimisation of the organizations underlying processes and activities so as to achieve more(prenominal)(prenominal) and more efficient results.Business overture Techniques atomic identification number 18 very beta and beneficial for the disparate types and sizes of companies in each and every sector so as to remain competitive and relevant in todays challenging business environment. Implementation of Business Improvement Techniques usually requires a dynamic culture win over throughout the whole organization. The organizations that have been in a position to successfully accomplish a philosophy of never-ending improvement over the time have had benefits of reduced cost s of operations reduced inventory costs, increased sales and profitability, improved team knead and better client service level and thus principal to guest satisfaction. These Business Improvement Techniques dope apply to the organization as a whole in any particular sector of the economy scratch from service providers, to government departments to the health cargon sector so to construction, land and besides from manufacturing.The techniques be too very pivotal in the increment of a vision, goals, objectives and a strategy towards yielding extraordinary gains in the business. Through these Techniques proper mapping and identification of key processes is d ace and the information is systems are designed to ensure that information flows within the whole organization in the properly order and manner. A nonher benefit of these techniques is that through them defective points are noted or identified and areas or points of dispel are in like manner identified. Recommendatio ns in terms of ways and methods of introducing business those which will eliminate waste and provide bottom line benefits to the business are formulated.Despite the fact that Business Improvement Techniques have numerous bottom line benefits the techniques still have many limitations. The process of Business Improvement Technique is quite a engaging and tiresome it surely requires diligence, dedication and concentrated efforts for it to bear fruits or yield the expected results. The process is also usually costly to implement despite having very many an spick-and-span(prenominal)(prenominal) benefits it requires resources in terms of technical and experience manpower, hiring of experts and also machinery, tools and equipments especially for a manufacturing organization so as to effect the recommended changes.Thorough and detailed analysis of any available information and pull together of entropy may in a way strain the organization. In-depth cultivation of workers and staff , regular monitoring and evaluation thorough planning, scheduling and organizing are also racyly inevitable if the improvement technique is to succeed. It also takes time for the benefits of implementing the improvement technique to be realized at times even historic period after the start of the implementation process. Resistance to changes by some citizenry in the organization is also an expected limitation in an campaign to improve the business, some factions in the organization may feel be and insecure with the changes brought about by the techniques in terms of changes to processes and systems in the organization. At times workers and even some customers tend to oppose changes to the live processes and systems. Difficulties can also be experienced before the new established or streamlined processes and systems can become fully operational and functional.The Sigma sise Sigma sixer is a powerful management philosophy business improvement technique developed by Motorol a that champions stage setting of very high objectives, collection of data and its analysis to give out results to a really high point so as to reduce defects in the products and services offered by the organization. The raillery Sigma originates from a Greek letter sigma which is usually partd to denote variant from a certain set standard. The Six Sigma philosophy is based on the fact that if you take dole outation of the many number of defects through measurement there is in a process then it becomes easier to figure out how to eliminate the defects systematically and get near to perfection as much as realizable. For Six sigma to be achieved by any organization or family it cannot be producing more than 3.4 defects per angiotensin converting enzyme million opportunities in which scale an opportunity is taken to mean a chance for nonconformance.Sigma Six has sextet processes namely Six Sigma DMAIC and Six Sigma DMADV, each term deduced from the major move in the proc ess. Six Sigma DMAIC is a process that deals with defining, measuring, analyzing, improving, and controlling of existing processes that travel by beneath the Six Sigma standard or specification. Six Sigma DMADV deals with defining, measuring and analyzing designs and also verification of new processes and even products that are striving to achieve the Six Sigma quality. All Six Sigma processes are implement by Six Sigma green Belts or Six Sigma Black Belts, which are then overseen by a Six Sigma Master Black Belts. Six Sigma proponents argue that it has mega benefits to the company. These benefits include an up to 50% process cost decrease, cycle-time improvement, a little waste of materials and companys resources, a better understanding of customer demand and requirements, work out customer satisfaction, and also more reliable products and services that can be trusted.Six Sigma can be a really costly improvement technique to implement and can even take several age before th e company begins to see its benefits or bottom-line results. Some of the Companies that have unspoiled and still practice Six Sigma are, General Electric, Texas Instruments, Scientific-Atlanta, Allied Signal and many others.Cases showing application of Six Sigma Technique in the Industry The samples below shows some Six Sigma projects evidencing the improvements and changes to processes and systems that were ongoing some of which were very problematic and throng would wonder whether those problems could have genuinely been saved at all at all. It is the Six Sigma technique or approach that carrys to these companies identifying their problems and thus be in a position to seek solutions to them many of these projects that were tackled by Six Sigma teams would not have been tackled or addressed at all. Some of these sample aspects are standard Case 1 CANCEL THAT NEW PLANT The case bear on a highly successful new pain-killer drug, a pharmaceutic company launched plans to s et up a $200 million business facility so as to double its capacity. As the effort of setting it up were starting some people from the company who were new participants in the companys Six Sigma effort resolved to investigate some of the short-term blackguards that can boost action in the existing plant. As they collected data, the group or participants first realized that it was provided about 40 percent of the drug that was being packaged was in operation(p) or could be used. Looking barely, they discovered that the sealing method that was being used for the drug vials was very inconsistent that some of them would not be completely closed, while at the same time others were too long to fit in the box. The team thus used a number of testing and fine-tune of theSealing process by use of different design experiments methods and finally determined the very best combination of inputs or factors that is the time, temperature, distance and so on that could be used to ensure a goo d seal. Effecting these changes and an addition of few $50 parts to regulate and change the sealing equipment was done and there was no need of establishing the new plant.Sample Case 2 REPAIRING REPAIRS A major organization dealing with appliances remediate realized the need to improve its capacity to return items to the customers in accordance of rights to when the goods were promised to be returned. Many are the times that repairs were late and the customers became disappointed when they would call in or make by the organization premises to choice up their appliances or computer.A multi-level DMAIC team decided to narrow their scope to cardinal repair locations and to diligently and carefully analyze all the causes leading to late repairs. The first discovery is that the time taken to repair one product was only part of the problem and that the time taken to channel appliances back and forth from repair shop to the customer site also was the main and big contributor to d elays or missed dates. Based on the findings together with the cost/benefit analysis the team in helper with other colleagues engaged in the two pilot facilities or projects implemented a few changes so as to streamline the process and increase the number of appliances being returned to customers when promised.Lean Sigma on Manufacturing Systems and its Importance in the performance system The value of Lean Manufacturing System is best comprehended when at the particular time that its impact of change on economics is mighty understood. This manufacturing engineering philosophy is based on designing a manufacturing process or system that very well blends together the essentials of minimizing cost and maximizing profit. The main fundamentals with these systems are Labor, Materials and Machines or Equipment referred to as 3Ms of manufacturing. A very well balanced 3M results in Maximum utilization of both skilled and unskilled labor optimal use of the plant size limpid traffic movement of materials, labor and automotives. It can also lead to negligible grand total manufacturing costs of the products being induced Reduce investment cut labor requirement and utilization of more productive equipment. Disposition of less productive or unproductive equipments Flexibility to keeping in grounds with market and customer changes and also Increase Return on clams Asset are other results of use the 3M fundamentals.Three tinctures involved in the accomplishment of the ultimate manufacturing engineering lean philosophy namely The first step is to design a simple manufacturing system one commences the process of system design as simple as possible with just a low volume through the system. The second step is the realization that there is always a room for improvements and thus refining the first step as much as possible. The third step is to continuously work on and improve the lean manufacturing system design concept with addition of the appropriate insertion of and balance of automations, conveyors and in necessary cases the buffer stocks. Additional concepts can be generated that could lead to satisfaction of product and the technical marketing requirements of the products. Through a thorough re-examination of intra- and inter- technologies, through past times output process errors and the lessons learned. The competitive analysis of techno-communication may be relevant and finally selection of the proper manufacturing system concepts to be adopted for further considerations or developments should be based upon a thorough analysis performed or done in accordance with the established selection criteria.Consideration of two manufacturing systems that when they are combined give rise to Lean Manufacturing system that is the play Manufacturing System and Agile Manufacturing System. Designing a Simple Manufacturing System through flow manufacturing is a time-based process that joins together a smooth production system without any disruptio n. Rapidly and smoothly flowing materials from raw materials to sunk goods through systematic balancing of the laborers or operators, the machine and equipment to customer demands or requirements. The objective of Flow Manufacturing is to provide the ultimate response and also bring in the customer requirement, benefits of this goal being to decrease the Total merchandise pass Time, increased productivity and also increased the per capital equipment utilization. In this system of Flow Manufacturing, the performance and output is measured by the Total ingathering circle Time also referred to as the Critical Path.Total Product Cycle Time is the longest lead time path right away from raw materials to undefiled goods it is the quickest possible response to a customer order with finished products. Lead Time consideration and analysis is derived from the Critical Path which helps us to outline opportunities so as to reduce or eliminate Non-Value-Adding activities and in the process shortening the Total Cycle Product Time. When reducing the variations in the rate of flow in the manufacturing system, the lead time will be reduced. These variations can be reduced through random downtimes, higher uptime, through quick changeover, lower downtime and also through improved quality through error proofs, self checks, and equipment product concentrate on cellular layouts.Agile Manufacturing is quite a profitable manufacturing system that is near inter-twined to the concept of Flow Manufacturing. It goes further and builds on the Flow Manufacturing concept to further reduce the lead time, optimize asset utilization or use and build to customer demand by focusing on being able to aptly serve to customer requests and demands. It has an assumption that the customer requirement or specifications and volumes which is based on continuous changes. Program lead time is the form of measurement of Agile Manufacturing performance. The main goal is to have a system that has a sm ooth flow of material while at the same time maximizing the value added activities of the operator. There are other situations in the system design process that requires special consideration such as situations include Manufacturing Process, Manufacturing System, Value Added (VA) activities and the Non Value Added (NVA) activities.The manufacturing process entails the equipments used to create, to alter, to assemble, to measure and tests the product with the objective of meeting a pre-determined product requirement. This equipment includes machines, tools, fixtures, and gauges such as drills, grinders and test stands. The manufacturing system involves the combination of labor and manufacturing process which are then linked together with materials handling both manual or alter so as to move the material or product from one manufacturing point to the next process and to the next until it is processed into a finished product. VA or Value Added is any activity that is performed to a p roduct as it moves along the production process that the customer perceived as actually addition of value to the product. The NVA (Non Valuable Activities) are all the activities that are associated with the production process that happen not to be adding any value to the product and thus not necessary to be performed but it is still still performed at the current moment awaiting the emergence or arousal of ken on availability of better methods to replace it.In Lean Manufacturing up to now the manufacturing cost does not necessarily have a steep drop as the volume requirements or demands of customers changes. This is because of the product tractableness and also equipment tractability that can be very well combine into the Lean Manufacturing System. This system is mostly characterized with investment which are done as required, more flexible equipment, more adaptability to uncertain markets in terms of volumes and products and also characterized with smaller capacity increment s and more product(s) flexibility.Lean manufacturing system design needs to be continuously improved so as to aptly respond to the customer requirements and to ensure this is by having flexibility of equipment and have the capability to scoff it with the product flexibility. Having uncertain customer requirements makes it important to examine the manufacturing costs over a range of volumes also been very keen not to produce beyond the requirements. This system is characterized with investments committed upfront which is usually quite high more rigid and complicated equipment and larger capacity increments with high customer volume demands or requirements for long periodsLean Manufacturing System has potential for great profitability which highly depends on utilization of its resources that is the 3Ms in terms of the materials miserable the Value Activities or VA, man or labor working by adding value to the product, machine running in a manner that is more productive. Lean Manufac turing System can be successfully adopted in new manufacturing system or environment, in an existing manufacturing system requiring capitalization, new equipments or even in product relocation.In conclusion given(p) the increasing competitiveness in the market place it would be suicidal for a business to ignore continual improvement in its systems and operations. Manufacturing companies specifically will always continue to face increasing pressure to improve the quality of their products, to increase productivity and to reduce costs with the available scarce resources. Use of the right Business Improvement Techniques to ensure continued improvement of the business to as to keep afloat of competition and deal with changes in its environment. From this paper it is clear that Business Improvement Techniques dramatically decreases the waste orbit in the business operations and also reduces the Inventory and floor blank space requirements. Creation of more robust production processes and systems and also appropriate material delivery systems are established and there is improved layouts for more flexibility in business as a result of the Business Improvement Techniques and thus should be a priority for any business to consider embracing.ReferencesMarcos, M. (2012). Advances in manufacturing systems selected, peer reviewed papers from the 4th Manufacturing Engineering Society world(prenominal) Conference, September 2011, Cadiz, Spain. Durnten-Zurich, Switzerland Trans Tech Publications.Martin, T. D., & Bell, J. T. (2011). New horizons in standardized work techniques for manufacturing and business process improvement. Boca Raton, FL CRC Press.Meyer, U. B., & Creux, S. E. (2009). Process oriented analysis design and optimization of industrial production systems. Boca Raton, FL CRC/Taylor & Francis.Olaru, A. (2012). Optimization of the mechanical engineering, manufacturing systems, robotics and aerospace selected, peer reviewed papers from the 7th internationalis t Conference on Optimization of the Mechanical Engineering, Manufacturing systems, Robotics and Aerospace (OP. Stafa-Zurich TTP Trans Tech Publications.Rogers, D. (2011). The future of lean Sigma thinking in a changing business environment. Baco Raton, FL. CRC Press.Source document