Analysis The Application Of 6σ And Lean In TFASS

The only one thing that can not be change that is the change. For human history , every step with the progress is because the change. The succeeded company always introduce into advanced management methods and continuously improve themselves.TOYOTA company launch their first car in 1936, it had 40 years delay against other big car company in the occident country. But during the recent years, it became the biggest car maker in the world. Its retained profits over 10 billion dollars in the nearly five years. In 2007, the annual primary income of TOYOTA is 204.746 billion dollars that is higher than the three biggest American car maker GM, FORD and CHRISLER total amount. New TOYOTA became to the sixth biggest company in the world, In 2008, during the Jan to Jun Toyota sold 4.716 billion cars in the worldwide, higher than the original car maker GM company. Why TOYOTA have such effort, the profit from it own manage system– TOYOTA production system, also calls Lean production."Implementation of six sigma is a great opportunity for General Electric to achieve great development, improve innovation ability and satisfy their customers"said Jack·Welch, Chief Officer of GM. Since beginning of this century, the six sigma management methods had became famous all over the world. Some successful businesses reduced cost and get more profit through implementation of six sigma management. Following are sets of data: Motorola's business turnover increased 5 times, annual profit increased 20%, $14 billion savings in total and stocks price increased 21.3% during its implementation of six sigma methods from 1987 to 1997. During the implementation of six sigma, the Allied Signal's productivity improved 6%, and the company profit increased 13% in 1998, and they have $0.6 billion total savings, and the stocks price increased 27%. General Motor gained $0.75 billion profit in 1998, and gained $1.5 billion benefit and gross profit increase 15% in 1999 during period of six sigma implementation.The thesis discussed six sigma and lean management's theory and methods through the practice in the TRW FAWER Automobile Safety System Co,.Ltd. It focused on how to implement six sigma and lean improvements process as well as the method and the combination of six sigma and lean management system and management method.There are 4 Chapters in this thesis. At the beginning is the foreword, which describes the purpose, scopes, theory basis and the analysis result and the signification of the study.The thesis in Chapter one analyzes the background of the TFASS company and describes the possibility of the company implementation of the six sigma and lean production as cost reduction methods and it's organization frame. The thesis in Chapter two introduces the TFASS cost reduction methods six sigma and lean management theory, statistic tool, key roles and their function in the six sigma management as well as the Minitab software. Sigma method is that the project team seeks a solution based on the collected data, and using statistic tool. Nowadays, the boring and complicated statistic calculation can be done by a computer, and the statistic software will help people to quick learn the tooling and find out the relationship between events. For Lean production, the base fundamental is eliminate waste, reduce the cost, all people join and continuous improment.The thesis in Chapter three introduces some six sigma and lean implementation cases of the TFASS company: Improvement of the pigment equipment of the steering wheel. The six sigma improve process (DMAIC) and the detailed implementation steps have been expounded during the description the case and also some lean production examples to show how can they reduce the costs.The thesis in Chapter four analyzes the background of the company and describes the possibility of the company implementation of the six sigma and lean production. This Chapter also presents the detailed methods as well as how to avoid the mistake during the implementation of the six sigma and lean production.After discussion and analysis, the thesis make a final conclusion that six sigma and lean management are two of main modern business cost reduction methods. If the company want implement the lean and six sigma method, it must find the problems of itself. Lean and six sigma can help the company find problems also provide the solutions. Actually these two manage methods not only can implement in the manufacturing company but also can use for other business area.A good management team with leading of a top management and a sound business culture may make the implementation of six sigma and lean smoothly. Just like any other management method, its all need a period that the difficulties may occur and the key is that the team, who will promote this two methods should be really known and the top management must provide fully support for the promotion of the six sigma and lean production. If the boss really know the six sigma and lean management and they can personally push the project, the result will be the different. So the qualified team member and support from the top management with a good team cooperation, the company surely can implement the six sigma and lean smoothly.