Combined Usage of Theory of Constraints, Lean and Six Sigma in Quality Assurance of Manufacturing Processes

Abstract

Classic intention, which pursues the management of any company – is to improve the quality and competitiveness of its own production, aiming at the end to speed up the receiving of profit. Such an implementation is primarily made possible by optimizing production processes. The manufacturing processes are influenced by various factors that may lead to deviations from the process requirements. Management of processes is needed to counteract such change in the process.Processes that are not managed, can lead to the production of a large number of defective products earlier before the detection of nonconformity, causing significant damage and lead to disruption of production schedules. It is important to develop an effective system of management and control, capable of detecting variations in the process as early as possible so you can take corrective action before it is produced by a large number of defective products. To optimize production processes in quality assurance the following systems have been known as Theory of Constraints, Lean, Six Sigma. Typically, these systems are used separately. However, their combination and comprehensive utilization can be more efficient and can give a much better result.As a rule, first by using Theory of Constraints (TOC) the bottleneck is defined – weak area, which is an obstacle of improving of the quality and efficiency of the company and profit increasing. Then Lean tools manage this area. And the next phase includes Six Sigma, which allows you to receive a significant increase in the effectiveness and efficiency of production and profit.Each of these techniques is unique and their complex usage is important in managing the quality of processes and products.

State of the Art of Lean Six Sigma and Its Implementation in Chemical Manufacturing Industry Using a Bibliometric Perspective

“…Cost reduction: LSS implementation led to significant cost savings [51,52,59,61,66,69]. Quality improvement: LSS enhanced product and service quality and customer satisfaction [55,57,70]. Cycle time reduction: LSS helped streamline processes, eliminate non-value-added activities, and optimize workflows [61,69].…”

“…Continuous learning and innovation: LSS encourages a culture of continuous learning, problem-solving, and innovation. Chemical manufacturers adopting LSS embrace a mindset of ongoing improvement and foster a culture of employee involvement and engagement in driving innovation and process enhancement [32,56,57,70].…”

Statistical Methods for Quality Control: A Tool for Data Analysis in the Statistica Package

“…Окремі аспекти дослідження статистичних методів аналізу бізнес-процесів та підготовки фахівців Data Science висвітлені у працях вітчизняних статистиків С. Герасименка та Г. Голубової [7], К. Семенової і К. Тарасової [8], Р. Моторина [9] тощо. На методах контролю якості зосереджена окрема увага у працях Л. Демчук та Р. Байцара [10], А. Ткаченко й М. Іванової [11], Т. Фурмана і М. Загоруйко [12] та багатьох інших, оскільки відповідні статистичні методи застосовуються в різних галузях науки й техніки.…”

Collaborative Networks Management from a Theory of Constraints Perspective

“…Once the purpose of each system's component has been defined, the TOC concentrates all its efforts on promoting improvements that directly translate into system purposes or objectives and, inevitably, into increasing overall performance. These advantages may even increase, when TOC is combined with other management paradigms [9].…”