Page 365 - Design for Six Sigma for Service (Six SIGMA Operational Methods)

Design and Improvement of Service Processes—Process Management 325

Manufacturing Process Analysis
Typical activities in manufacturing and manufacturing support include
• Production operations
• Job setup
• Tool fabrication and repairs
• Shipping and receiving
• Shop floor control and project management
• Quality control and quality assurance
• Equipment repairs and preventive maintenance
• Scheduling
• Production planning
• Software programming
• Facilities planning
The resources needed for manufacturing range from processing equipment,
like machine tools, to material-handling devices required to move material.
Over and over again, the evidence has been upheld that good statistical
control of production processes, training for operators and support staff, and
preventive maintenance of key equipment are the primary determinants of
manufacturing success.

The common problems in the manufacturing process include
1. Low throughput and efficiency
2. Excessive production lead time
3. Excessive work in process
4. Late orders
5. Excessive rework
6. Poor quality
7. Chaos, confusion, lost parts
8. Excessive production cost
9. Lost orders
10. Poor safety record
These common problems are often caused by
• High process variability
• Poor incoming raw material
• Poor operator training
• Unbalanced processes
• Excessive setup times
• Poor process design and validation
• Poor workstation and plant layout