Hi Everyone there................
Can anybody tell me about connection in KANBAN-LEAN MANUFACTURING-SIXSIGMA. ? ? ? Even I will be happy to know the real industry example on use of this trio in combination.
I want to know about the link they have............
28th September 2007 From India , Mumbai

Hai Geet,

I am new to this forum....

i am working as Indusrial Engineer in MNC, focusing on Process Improvements.. I would like to share my exp with u...

First, Kaizen....It is a continous improvement where you need apply the concepts of Qulaity Control tools, TPM , TQM , IE etc...Utlimately improve the processes...

Second...Lean Manufacturing...Which is broad subject and mainly concentrates on eliminate of wastes other wise called as Non-Value added activities which are existing in the processes. And it also covers reduction of lead time...One of the popular technique called Value Stream Mapping (VSM) is mainly applied for this purpose.

Third, Six Sigma--Its different scenario, focusing on improve quality rate in other terms reduction of defects..which is helping process improvement activities (kaizen).

It has got variety of statistical techniques, tools, quality control tools for successful completon of the project..

I hope this would feed you something atleast..

Letus expect some more from our friends.....


25th October 2007 From India , Hyderabad
Sorry to reply after such a long time...
I am a new user and me doing ops mgmt course in SIOM..
To answer ur query..
lean helps in improving process velocity and reduces the lead time whereas six sigma aims to improve the process stability... and aims in reducing the defects both these techniques go hand in hand...thats the reason why nowadays both are applied together in services...
28th November 2007
29th November 2007 From India , Delhi
feel free ask if wanna some more about any thing in production management regards Rajeev Singh
29th November 2007 From India , Delhi
heyy Geet.................

Answering ur Question........

KANBAN--- It is a sort of Signaling system where u can come to know abt the Present Status of raw Material i.e Quanity remained & can come to know abt the time by which u need to Re feed or Re load the machine to avoid it from Unnecesssary Raw Material shortage & Stoppage therby, as well it is indicator of the opertor speed/effeciency of working etc..


Lean Manufacturing is a Broader concept which Includes Japanees systems like KAIZEN(Continuous Improvent),KANBAN,JIT as well Quality Systems such as TPM,TQM & broadly focuses on continuously Improving process or making it stable that gives best results with Low within & Between variations consistantly with low costs of conversion by removing Non Value Adding processes.It also a sort of benchmarking ur process as per standards & using various TOOLS to Implement it....

And Finally SIX SIGMA------

It is a Project based Quality ( Not necessarily Continuous) system that ensures that the company is achieving the Number of Defects as per the SIGMA level they r operting in & continuously meeting customer expectations. It can be Done through various tools such as DMAIC (Define,Measure,Analyse,Improve,Control) strategy through perioding audits
4th December 2007 From India , Thana
Shastry S N

Adding to the comments here in..

Kanban is a lean management technique specifically used for Inventory control as part of Just in Time (JIT) "Pull-System" framework.

A typical implementation model is a Two Bin system, where parts/items/sub-assemblies that are being used in a manufacturing assembly process are stocked in two bins.

When the first bin gets empty, there is a re-order card at the bottom of it, which is picked up and replenishment of parts is initiated. During the lead time taken for replenishment, the parts available in the second bin is used to feed into the manufacturing / assembly operations, which also has similar re-order card at the bottom. By the time second bin gets empty, the first bin is replenished and the cycle goes on.

This mechanism helps in keeping tight control of inventory (Stock) of parts so that excessive stock is not carried. At the same time, the bin size (quantity of parts to be kept in the bin) is decided in a scientific manner based on production demand, supply lead time and delivery quality so that there is no stock out (parts not available to feed into manufacturing).

A very simple example of Kanban is the 15 litre Mineral drinking water containers that are used in companies (now a days in many houses too!!) where one container is kept on top of the other.

As the bottom containers (with the tap) gets emptied, water from the top one flows. When the top one becomes empty, it is sent for replenishment so that the replenishment comes in by the time the lower container also gets empty. This is not the perfect example of Kanban, but serves to illustrate the point in a simplified manner.

Kanban is widely used in Japanese (and many Indian) mfg organizations to control inventory at an optimum level and only source what is needed for daily operations thereby avoiding waste of money, space, resources and organizational energy just to manage excess stocks. Kanban looks simple as a concept, but it needs a tight co-ordination between supplier and customer functions, a strong reliability in terms of lead time to delivery, quality level of items/parts among other factors.

Best regards,

Sethu V

E: enquiry-at-examplecg.com

eXample Consulting Group

8th April 2008 From India , Bangalore
Kanban is not a technique but is a visual signal as you have illustrated with the mineral water container example.
This signal can be an empty container/crate, a card, an empty space etc. which signals to a process owner how much is to produced/made and handed over to the next immediate process. Kanban sognals always flow from downstream processes to the upstream processes in JIT system to ensure that the system produces what the customer wants at the time he wants.
22nd May 2008 From India , Bangalore
Kanban is a tool / technique used in lean manufacturing or the Toyota Production System (TPS). Although it refers to manufacturing, the TPS can be used in services also.
Six sigma is an independent technique used to reduce number of defects in any process or p[roduct. If you are following TPS or a similar system, you will probably not need six sigma. Six sigma becomes project and presentation oriented, and sometimes drifts away from the gemba.
6th June 2008
Hi All,
Really good to see the discussion we are having, on Lean , Kaizen , Six Sigma. I'm from Japanese Mgmt Consulting firm,working last 10 years with various industry.
Kanban as explained by few gentelman, is absolutely right. It's tools for Replishnishment of material from the point of use. And it's part of JIT system, Kanban card can be hard copy paper or electronic Kanban thru software integration.
Lean means Fatless, it's tool for Mapping the process of Value Added & Non - Value added work / activity thru Value Stream Mapping.
Kaizen means Continual Improvement. It's tools to implement, the eliminate Non-Value added work / activity / service through it's various techniques. The strong point of Kaizen is result oriented thru most simple way of approach. Any Non-Value added activity / work can be identify by Observation 73%, self data collection 20%, & 7% common sense to the approach.
Six Sigma - A Bullshit device to make problem long & strong. Long term strategy planning for even simple problem to eliminate. Only for limited resourse team which is working for, not for process owner or operator who works in it. yes , Six Sigma one good tool when you can't identify the problem and you need to solve it. These only related to Quality only. Not for Productivity, Efficiency or Cost.

Hope some guys feel bad on my comment & some understand..


5th September 2008 From India , Gurgaon


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