Action Steps
The best contacts and resources to help you get it done

Learn to flow with process improvement in manufacturing using Lean Manufacturing

While managers commonly assume Lean Manufacturing is a set of business tools the assembly line can adopt to identify waste in the production process, this philosophy sums up as getting the right things to the right place at the right time in the right quantity to achieve perfect work flow. In one word, lean means simplify. It's less about spotting particular sources of waste; it's more about the entire process flowing as smoothly and trouble-free as possible-manufacturing as a perfect dance, partnering people and process all along the supply chain.

I recommend: Infor, the world's third largest business software company, hosts a Lean Manufacturing resource library where you can sign up for webinars to better understand the basics of Lean Manufacturing. Productivity offers consulting, training, seminars, conferences and certification programs revolving around Lean Management techniques.

Adopt a philosophy of productivity and process improvement with TQM

Compared to the other two MPI methods, TQM encompasses more of a general management philosophy for directing quality than a specific process. Japan's version of TQM is comprised of four aspects. First, start with the idea that your product will work as it's meant to. Couple this with studying how the end user operates the product to provide a starting point for the production process improvement. Third, incorporate aesthetics into the production process; not only must the product work, it must satisfy the consumer as he uses it. Finally, measure and repeat the procedures-replicate the process.

I recommend: Organized Change embodies that quality management philosophy, preferring to work on production process improvements than lock in on any one phrase such as TQM versus re-engineering. Berthelot Consulting not only supplies consulting and training expertise, but can assist you in writing policies, manuals and marketing materials to promote TQM efforts inside and outside your company.

Measure MPI performance with Six Sigma

Unlike the first two MPI methods, Six Sigma owes its existence to statistics, rather than just using stats as a measuring tool to support the system. The term Six Sigma itself refers to the ability of manufacturing processes to operate with 'Six Sigma quality' over the short term, which means their long-term defect levels fall below 3.4 defects per million opportunities (DPMO).

I recommend: Technical Change Associates conducts Six Sigma training boot camps and certification programs. ActiveStrategy Consulting offers green belt, yellow belt, black belt and master black belt training and certification programs plus other workshops.

Helpful advice for making the most of this Guide

• •  Before launching any process improvements in manufacturing, examine your company first. How do you view your company within your industry, against competitors, in your customers' eyes? Do you emphasize internal process, reliable components, strong relationships, innovative features? Can you count on management to own the new process? How will you know if you've succeeded? All good intentions can be sabotaged by a poorly matched MPI.