PROCESS IMPROVEMENT

Process improvement is a vital aspect of managing a business, and it can take many different forms. Whether you’re looking to optimize your supply chain, enhance your quality control processes, or improve your customer service, the goal is always the same: to make things better. At Archimedes Consult, we understand that every business has unique challenges and objectives, and we offer tailored solutions to help you achieve your goals. Our team of experienced consultants has a proven track record of delivering measurable results, and we use a data-driven approach to identify areas of improvement and develop customized strategies that deliver sustainable value.

Every business wants to save money, increase profits, and improve efficiency. At Archimedes Consult, we take a holistic approach to measuring the value that process improvements can bring to your business. Our focus is not just on raw dollars, but on labor hours, quality improvements, reduced cycle times, better customer experiences, and improved work environments for your employees. We work closely with you to understand your business needs, and we develop solutions that are practical, actionable, and tailored to your specific situation. No matter what size or type of business you have, process improvement is a critical component of success, and we are here to help you achieve your goals.

STEPS OF PROCESS IMPROVEMENT

We follow a specific process on our automation consulting projects to ensure the proper tracking and deliveyr of value by the automation to the process.

DEFINE

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Define an area of improvement, or known problem. It may even just be a selected area of focus. Clearly set the scope for what process you are trying to improve upon.

MEASURE

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Gather all of the data surrounding the area of focus. Key Performance Indicators (KPIs), volume data, time data, quality metrics, how many people are involved, and systems.

ANALYZE

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Analyze the data and derive outcomes based on experience, industry knowledge, feedback from users, global best practices, and management goals. Perform gap analysis.

IMPROVE

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Plan on how to change the process and review expected results. Agree upon implementation and execute project plan. Update documentation, ensure KPIs are being recorded.

CONTROL

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Ensure reporting is in place and being monitored to ensure expected results. Calculate true value add, and finalize value/effort calculation. Assign process owner and establish KPI.

GLOBAL BEST PRACTICES – IN DEPTH

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Six Sigma Methodology

Six Sigma is a widely-used methodology that is utilized to improve business processes and increase overall efficiency. It is a data-driven approach that aims to eliminate defects and minimize variation in the production process. This methodology was first introduced in the mid-1980s by Motorola, and has since been adopted by many other organizations around the world.

The term Six Sigma is derived from the statistical measure of standard deviation, where six sigma represents a level of quality that allows for only 3.4 defects per million opportunities. The goal of Six Sigma is to achieve this level of quality by identifying and removing the causes of defects and minimizing variability in processes.

The Six Sigma methodology is typically broken down into five phases: Define, Measure, Analyze, Improve, and Control (DMAIC). During the Define phase, the project team defines the problem and sets the project goals. In the Measure phase, data is collected and analyzed to understand the current process performance. The Analyze phase involves identifying the root cause of the problem and determining the impact of various factors on the process. The Improve phase involves developing and implementing solutions to improve the process. Finally, during the Control phase, the process is monitored to ensure that the improvements are sustained over time.

Today, Six Sigma is used across a wide range of industries, including manufacturing, healthcare, finance, and service industries. It is a highly effective tool for improving quality, reducing costs, and increasing customer satisfaction. Organizations that have successfully implemented Six Sigma have seen significant benefits, including increased efficiency, reduced defects, and improved customer satisfaction.

One of the most well-known success stories of Six Sigma is its use at General Electric (GE) under the leadership of CEO Jack Welch. In the late 1990s, GE embraced Six Sigma and implemented it across the entire organization. This resulted in significant improvements in efficiency and quality, as well as cost savings of over $2 billion. Other notable success stories include the use of Six Sigma at Motorola, which helped the company save over $17 billion, and at AlliedSignal, which increased its earnings by 28% in just two years.

In summary, Six Sigma is a powerful methodology that has been proven to be highly effective in improving business processes and increasing overall efficiency. Its data-driven approach and focus on eliminating defects and minimizing variability make it a valuable tool for organizations across a wide range of industries. By implementing Six Sigma, organizations can achieve significant cost savings, improve quality, and increase customer satisfaction.

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Total Quality Management

Total Quality Management (TQM) is a comprehensive management approach that is focused on creating a culture of continuous improvement, customer satisfaction, and employee empowerment. It is a philosophy that emphasizes the importance of quality in every aspect of an organization’s operations, from product design to customer service.

The roots of TQM can be traced back to the early 20th century, when pioneers such as Walter A. Shewhart and W. Edwards Deming began developing statistical methods for improving quality in manufacturing processes. In the 1950s, the Japanese began incorporating these methods into their own manufacturing processes, leading to the development of the quality control and quality assurance systems that would later become known as TQM.

TQM is based on the principle that quality should be built into every aspect of an organization’s operations, rather than being an afterthought or a secondary concern. It involves a continuous cycle of planning, implementation, and evaluation, with a focus on meeting or exceeding customer expectations and improving overall efficiency and effectiveness.

Today, TQM is used across a wide range of industries, including manufacturing, healthcare, education, and service industries. It is a highly effective tool for improving quality, reducing costs, and increasing customer satisfaction. Organizations that have successfully implemented TQM have seen significant benefits, including increased efficiency, reduced defects, and improved employee morale.

One of the most well-known success stories of TQM is its use at Toyota, which has been able to consistently produce high-quality vehicles with minimal defects. Another notable success story is the use of TQM at Xerox, which helped the company reduce costs, improve quality, and increase customer satisfaction.

In summary, Total Quality Management is a comprehensive management approach that emphasizes the importance of quality in every aspect of an organization’s operations. Its focus on continuous improvement, customer satisfaction, and employee empowerment make it a valuable tool for organizations across a wide range of industries. By implementing TQM, organizations can achieve significant cost savings, improve quality, and increase customer satisfaction.

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Lean Manufacturing

Lean manufacturing is a production philosophy and methodology that focuses on maximizing value and minimizing waste in all aspects of the manufacturing process. It is based on the Toyota Production System (TPS), which was developed in Japan in the 1950s and 1960s.

The goal of lean manufacturing is to eliminate waste and inefficiencies in the manufacturing process, including overproduction, waiting, defects, overprocessing, excess inventory, unnecessary motion, and unused employee creativity. By reducing waste and improving efficiency, lean manufacturing can help organizations increase profitability, improve customer satisfaction, and gain a competitive advantage.

Lean manufacturing is based on several key principles, including continuous improvement, respect for people, and the creation of value for the customer. It emphasizes the importance of involving employees in the improvement process, using data to drive decision-making, and optimizing the flow of materials and information throughout the manufacturing process.

Today, lean manufacturing is used across a wide range of industries, including manufacturing, healthcare, service industries, and government. It is a highly effective tool for improving efficiency, reducing costs, and increasing customer satisfaction. Organizations that have successfully implemented lean manufacturing have seen significant benefits, including increased productivity, reduced lead times, and improved quality.

One of the most well-known success stories of lean manufacturing is its use at Toyota, which has been able to consistently produce high-quality vehicles with minimal waste and inefficiencies. Another notable success story is the use of lean manufacturing at Caterpillar, which helped the company reduce costs, improve quality, and increase customer satisfaction.

In summary, lean manufacturing is a production philosophy and methodology that focuses on maximizing value and minimizing waste in all aspects of the manufacturing process. Its focus on continuous improvement, employee involvement, and value creation make it a valuable tool for organizations across a wide range of industries. By implementing lean manufacturing, organizations can achieve significant cost savings, improve quality, and increase customer satisfaction.

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Kaizen

Kaizen is a Japanese term that means “continuous improvement.” It is a management philosophy and methodology that emphasizes the importance of continuous improvement in all aspects of an organization’s operations, from product design to customer service.

The goal of Kaizen is to identify and eliminate waste and inefficiencies in the manufacturing process, with a focus on improving quality, reducing costs, and increasing productivity. It is based on the principle that small, incremental improvements can add up to significant gains over time.

Kaizen is often associated with the Toyota Production System (TPS), which was developed in Japan in the 1950s and 1960s. It is based on several key principles, including teamwork, respect for people, and the pursuit of perfection.

Today, Kaizen is used across a wide range of industries, including manufacturing, healthcare, service industries, and government. It is a highly effective tool for improving efficiency, reducing costs, and increasing customer satisfaction. Organizations that have successfully implemented Kaizen have seen significant benefits, including increased productivity, improved quality, and reduced lead times.

One of the most well-known success stories of Kaizen is its use at Toyota, which has been able to consistently produce high-quality vehicles with minimal waste and inefficiencies. Another notable success story is the use of Kaizen at the NUMMI plant in California, which helped the plant improve efficiency, reduce costs, and increase employee engagement.

In summary, Kaizen is a management philosophy and methodology that emphasizes the importance of continuous improvement in all aspects of an organization’s operations. Its focus on teamwork, respect for people, and incremental improvements make it a valuable tool for organizations across a wide range of industries. By implementing Kaizen, organizations can achieve significant cost savings, improve quality, and increase customer satisfaction.