Lean or Six Sigma or TOC (Theory of Constraints) - How to decide

S

suhasdn

#1
Hi frends,
I am new to this forum.
I am working in a leading manufacturing firm.
I always have a doubt in my mind that,
how do we decide on approach i.e. Lean or 6Sigma or TOC we should take for solving any problem.
how do we start the analysis.

It would be great if someone provides some useful insights and some additional links/reading reference.

cheers
 
Elsmar Forum Sponsor
U

Umang Vidyarthi

#2
Re: Lean or Six Sigma or TOC how to decide

Hello suhasdn, :bigwave:Welcome to the cove :bigwave:

Believe me, no one on planet earth can give a straight answer to your poser, for the simple reason that each type of problem needs different approach and method for its solution. For example what needs 'is-is not' can't be solved by 5-Why or why-why analysis. There are serious implications of falt-tree analysis which can not be answered by 8-D analysis and so on.

Another and very important fact to remember, even after identifying the right method for analysis, one has to approach with full understanding or else you will be misled. 5-why analysis is considered the easiest of all, but it is the most misleading one, traps you in your own cobweb. Without reaching the root-cause, you are led to believe reaching the (illusionary) root cause.

Therefore the pre-requisite is to have a thorough knowledge and understanding of all the tools, before embarking on the journey of problem solving. Else, there is an old and my favourite from Maslow: 'If the only tool you have is a hammer, every problem looks like a nail.'

Umang :D
 

Jim Wynne

Staff member
Admin
#3
Re: Lean or Six Sigma or TOC how to decide

Hi frends,
I am new to this forum.
I am working in a leading manufacturing firm.
I always have a doubt in my mind that,
how do we decide on approach i.e. Lean or 6Sigma or TOC we should take for solving any problem.
how do we start the analysis.

It would be great if someone provides some useful insights and some additional links/reading reference.

cheers
Welcome to the Cove. :bigwave:

I'm assuming that "TOC" is Theory of Constraints. In any event, you begin a problem-solving analysis by having a clear definition of the problem, and then you set about solving it, using whatever rational means are at your disposal. You have a big toolbox, and you should select the tools that are appropriate to the job at hand. For the sake of clarity, the things you reference aren't tools, per se. You don't need SS in order to use statistical analysis, or to define the problem. You don't need lean (again, per se) in order to realize that your processes are inefficient.
 
S

suhasdn

#4
Re: Lean or Six Sigma or TOC how to decide

Welcome to the Cove. :bigwave:

I'm assuming that "TOC" is Theory of Constraints. In any event, you begin a problem-solving analysis by having a clear definition of the problem, and then you set about solving it, using whatever rational means are at your disposal. You have a big toolbox, and you should select the tools that are appropriate to the job at hand. For the sake of clarity, the things you reference aren't tools, per se. You don't need SS in order to use statistical analysis, or to define the problem. You don't need lean (again, per se) in order to realize that your processes are inefficient.
Thanks Jim & Umang,
I understand that no problem has straight solution when we speak about lean and 6sigma.
In my current job I am facing the same problem.
And the same question was asked to me in an interview. "if an organization asks you to improve the performance, what approach will you take, lean or six sigma e.g. a retail company"

Appreciate your replies

cheers
 

Stijloor

Staff member
Super Moderator
#5
Hi frends,
I am new to this forum.
I am working in a leading manufacturing firm.
I always have a doubt in my mind that,
how do we decide on approach i.e. Lean or 6Sigma or TOC we should take for solving any problem.
how do we start the analysis.

It would be great if someone provides some useful insights and some additional links/reading reference.

cheers
To quote Dr. W. Edwards Deming: "What is your aim?"
What is it you're trying to accomplish?

Solving problems? Is that it? Problems come in many disguises and sizes.
And on top of that; many differing opinions depending on who you ask.

I agree with Jim. Define first. Next, get agreement followed by prioritizing problems based on mutually agreed upon criteria.

Then, only then decide what tool(s) is(are) most appropriate. :yes:

Stijloor.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#6
These are all good argument in a practical or academic setting, but when confronted with the question in the context of an interview question, you have to be wary of a preconceived 'correct' answer - much like an ASQ exam.

Without dwelling on the topic, one might state that in a retail setting the key is getting the product from the manufacturer to the customer with the least amount of effort and overhead. Lean provides tools to aid that. If there is a need for a systemic measure that needs investigated or corrected as a part of that flow, there may be statistical tools in the six sigma portfolio to deal with that.

Beyond that, the specific situation will bear the evidence of which tools are best.

I would think most people interviewing will have all they need from that - anything more will glaze them.
 

Helmut Jilling

Auditor / Consultant
#7
I would take the approach they are all good tools, and benefit the company. Jim Wynne already explained that aprt. They should not be looked at as one against the other. They are the same tools, only focusing on different parts. Lean more on simplifying ("leaning") an activitiy, and 6Sigma on tighter process control. TOC fits in there, perhaps a little closer to Lean than 6S. I would add that all of this should be considered with ISO 9001 as a robust foundation to support it all. Lean is also a little easier to get people to understand and apply than 6S.
 
Thread starter Similar threads Forum Replies Date
N Student trying to apply Lean Six Sigma on a Construction project in my thesis Lean in Manufacturing and Service Industries 3
eule del ayre Lean Six Sigma for Quality Management System Lean in Manufacturing and Service Industries 10
Marc ASQ Lean Six Sigma Conference March 4-5, 2019 - Phoenix, AZ ASQ - American Society for Quality 0
Bev D ASQ Lean Six Sigma Conference March 4-5, 2019 Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 2
S Levels of Lean Six Sigma Certification Six Sigma 3
J Excellent Resource on Statistics / Lean / Six Sigma Book, Video, Blog and Web Site Reviews and Recommendations 2
Bev D ASQ 2015 Lean Six Sigma Conference: Bev D's Presentation Problem Solving, Root Cause Fault and Failure Analysis 9
Mikael Total Productive Maintenance vs. Lean, Six sigma, Business Process Reengineering, etc Quality Tools, Improvement and Analysis 9
Q Advice for the Implementation of a Lean/Six Sigma Program Six Sigma 9
N Lean Six Sigma Deployment Six Sigma 2
S Lean Hospital - Implementing a quality/lean/six sigma program Lean in Manufacturing and Service Industries 3
P Integration of Lean and Six Sigma Six Sigma 3
C Who should develop a LSS (Lean Six Sigma) project charter? Six Sigma 2
N What are three kinds of flow in Lean or Six Sigma? Lean in Manufacturing and Service Industries 4
N How to start Lean and Six Sigma in an Organization Lean in Manufacturing and Service Industries 7
V Excellent references on Lean & Six Sigma ...from MIT Book, Video, Blog and Web Site Reviews and Recommendations 0
V What is the difference between Six Sigma and Lean Six Sigma? Statistical Analysis Tools, Techniques and SPC 7
T Appropriate Lean Six Sigma Green Belt Project Proposal? Six Sigma 10
F Who manages QI projects? Quality or PMO? Managing Six Sigma and Lean Projects Six Sigma 2
T ISO 9000 / Lean Six Sigma Survey - University Study - Seeking Respondents ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 1
M ISO 9000/Lean Six Sigma Conference - Orlando March 2010 ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 1
J Where does Lean Six Sigma Originate? Six Sigma 5
J Need Book Recommendation: Lean Six Sigma for Healthcare Lean in Manufacturing and Service Industries 4
J Lean Six Sigma - Advantages and disadvantages Six Sigma 3
J Lean Six Sigma and the Environmental Benefits / trades off - your opinions please Lean in Manufacturing and Service Industries 9
S Strategy for implementation Lean Six Sigma - What kind of research? Six Sigma 4
ScottK Does your company use Six Sigma and/or Lean? Quality Tools, Improvement and Analysis 18
A Six Sigma and Lean Body of Knowledge (BoK) Six Sigma 4
B Benefits of Lean, Lean Six Sigma, Six Sigma, Balanced Scorecard - Making the case Quality Tools, Improvement and Analysis 3
Y Lean Six Sigma OR Six Sigma Six Sigma 3
M Lean and Six Sigma in supply chain operations. Lean in Manufacturing and Service Industries 1
Ajit Basrur Lean / Six Sigma Technical or Administrative Projects for Microbiology Laboratory Lean in Manufacturing and Service Industries 7
P The Significance of Lean and Six Sigma Outside Manufacturing - Thesis Questionnaire Six Sigma 0
S Student needs advice on his career in the field of Lean Manufacturing and Six Sigma Career and Occupation Discussions 14
W Need a link to a thread here - Discussed the difference between lean and six sigma Registered Visitor Articles Archive 9
A What is the difference between Lean and Six Sigma? Lean in Manufacturing and Service Industries 5
Govind Lean-Six Sigma: What do critics say? Lean in Manufacturing and Service Industries 13
J Lean Maintenance - Six Sigma's DMAIC guideline serving as a roadmap Lean in Manufacturing and Service Industries 3
L Lean Transformation - How do you get Senior Leadership engaged Human Factors and Ergonomics in Engineering 6
I New to LEAN but not to Quality - How to run Kaizen events Lean in Manufacturing and Service Industries 1
JAMESH Building a "Lean" Job Shop Training Program Training - Internal, External, Online and Distance Learning 0
D Lean and Elimination of QC Inspection Points in a New factory Lean in Manufacturing and Service Industries 9
J Lean MFG (manufacturing) process and Work order templates Lean in Manufacturing and Service Industries 6
T ASQ Lean 6sigma BB examination Six Sigma 3
Q How to start with Lean? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 8
R Lean's New Buzzword: Leader Standard Work Lean in Manufacturing and Service Industries 8
B Looking for Lean Manufacturing Articles in Spanish Lean in Manufacturing and Service Industries 4
L Lean Book for Basic Knowledge Lean in Manufacturing and Service Industries 0
0 Suggest a Lean Book for Upper Management Lean in Manufacturing and Service Industries 6
Mikael Lean Time Line (History and Theory) Lean in Manufacturing and Service Industries 5
Similar threads


















































Top Bottom