Advantages and Disadvantages of Six Sigma in Manufacturing

Six Sigma is an extremely common manufacturing strategy that is utilized by a large percentage of the industry. The methodology refers to a data-driven approach that is utilized by companies to upgrade their business processes. The method utilizes a five-step methodology that includes defining, measuring, analyzing, improving, and controlling the product process. 

These five-steps are implemented with the sole approach to eliminate defects at all stages within a company. Six Sigma defines defects as anything that is not within customer expectations. The goal is to apply a measurement-based approach that focuses on identifying and improving defects. Six Sigma is commonly integrated with the lean manufacturing methodology, in which it then becomes Lean Six Sigma. If you are attempting or considering to implement Six Sigma into your operation, there are various advantages and disadvantages associated with the methodology. 

Advantages and Disadvantages of Six Sigma 

Like any other manufacturing strategy, there are various advantages and disadvantages associated with the process. These advantages and disadvantages pertain to the following:? 

• Advantages: Six Sigma has provided a proven-track record of adding value and ensuring quality to the output of a business in the form of incremental improvements to a product or service. It could potentially also be used to optimize supply chain processes and increase customer satisfaction, which is a key component pertaining to quality. The benefits of Six-Sigma go beyond simple problem-solving and consider the entire production process from the raw materials to the end product as opposed to only the end product. Six Sigma is a proactive methodology that identifies and provides recommendations for potential problems before the company incurs any form of loss. 
• Disadvantages: No matter the amount of advantages there will always be some disadvantages. Six Sigma inspects the business processes minute-by-minute and generates substantial amounts of empirical data, leading to time-consuming and complicated procedures. Also, because it is a quality improvement process at its root, adoption of protocols often leads to an increase in costs. It is also important to consider that when Six-Sigma is implemented into a manufacturing process, problems arise as the company focuses on Six Sigma endorsed policies only and forgets about its specific mission statement or policies. 

A software that can easily aid with implementation of the Six Sigma methodology is PlanetTogether’s Advanced Planning and Scheduling (APS). Advanced Planning and Scheduling (APS) Software is being integrated into manufacturing operations around the globe and can easily aid the production process through cost reduction, waste reduction, profitability increase, and more. As other software such as ERP and MRP stand alone and lack specific insight, this is where APS software comes in to fill the gaps and increase overall productivity and efficiency .

Advanced Planning and Scheduling Software 

Advanced Planning and Scheduling (APS) software has become a must for modern-day manufacturing operations due to customer demand for increased product mix and fast delivery combined with downward cost pressures. APS can be quickly integrated with a ERP/MRP software to fill gaps where these system lack planning and scheduling flexibility and accuracy. Advanced Planning and Scheduling (APS) helps planners save time while providing greater agility in updating ever-changing priorities, production schedules, and inventory plans.

• Create optimized schedules balancing production efficiency and delivery performance
• Maximize output on bottleneck resources to increase revenue
• Synchronize supply with demand to reduce inventories
• Provide company-wide visibility to capacity
• Enable scenario data-driven decision making

Implementation of Advanced Planning and Scheduling (APS) software will take your manufacturing operations to the next level of production efficiency, taking advantage of the operational data you already have in your ERP.

Related Lean Manufacturing Video

 APS Resources