Hostname: page-component-848d4c4894-2pzkn Total loading time: 0 Render date: 2024-06-08T22:36:23.864Z Has data issue: false hasContentIssue false

Developing a lean measurement system to enhance process improvement

Published online by Cambridge University Press:  06 March 2014

Get access

Abstract

A key ingredient to underpin process improvement is a robust, reliable, repeatable measurement system. Process improvement activity needs to be supported by accurate and precise data because effective decision making, within process improvement activity, demands the use of “hard” data. One of the oldest and most established process improvement methods is Deming’s Plan-Do-Check-Act (PDCA) cycle which is reliant on the check phase, a measurement activity where data is being gathered and evaluated. Recent expansions of the PDCA such as the Six-Sigma Define-Measure-Analyse-Improve-Control (DMAIC) methodology place significant importance upon measurement. The DMAIC cycle incorporates the regimented requirement for the inclusion of measurement system analysis (MSA) into the breakthrough strategy. The call for MSA within the DMAIC cycle is to provide the improvement activity with a robust measurement system that will ensure a pertinent level of data during any validation process. The Lean methodology is heavily centred on the removal of the seven Mudas (wastes) from a manufacturing process: defects, overproduction, transportation, waiting, inventory, motion and processing. The application of lean, particularly within the manufacturing industry, has led to a perception that measurement is a waste within a manufacturing process because measurement processes identify defective products. The metrologists’ pursuit for measurement excellence could be construed as a hindrance by the “cost down” demands being perpetrated from the same organisation’s lean policy. So what possible benefits does enforcing the regimes of the lean and quality philosophies upon the measurement process have and how does this ultimately enhance the process improvement activity? The key fundamental to embed with any process improvement is the removal of waste. The process improvement techniques embedded within lean and quality concepts are extremely powerful practices in the drive to eradicate waste but there are numerous contextual problems with the application of the process improvement activity and its associated measurement system. The application demands of the organisation may be dependent on a number of financial and resource constraints which may introduce reasons not to apply stringent measurement methodology and practice. The failure of various process improvement activities due to poorly managed measurement activity has arguably never been comprehensively analysed. Process improvement activity theory fully embellishes the need for applied robust measurement systems, so how can process improvement and measurement be systematically aligned to gain benefits? The aim of this paper is to consider whether lean philosophies can be integrated and applied within measurement systems. The discussion seeks to identify if seven Muda exist within measurement systems and whether in doing so this will lead to benefits for process improvement activities.

Type
Research Article
Copyright
© EDP Sciences 2014

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

J.S. Oakland, TQM: Text with cases, 3rd edn. (Butterworth-Heinemann, Elsevier Ltd., Oxford, 2003)
J.S. Oakland, Statistical Process Control, 5th edn. (Butterworth-Heinemann, Elsevier Ltd., Oxford, 2003)
N. Slack, S. Chambers, C. Harland, A. Harrison, R. Johnston, Operations Management, 2nd edn. (Pitman Publishing, London, 1998)
J.E. Ross, Total Quality Management: Text, Cases and Readings, 3rd edn. (St Lucie Press, New York, 2000)
J. Bicheno, The Lean Toolbox, 2nd edn. (Picsie Books, Buckingham, 2000)
R.J. Schonberger, Japanese Manufacturing Techniques: Nine hidden lessons in simplicity (Collier Macmillan Canada Inc., 1982)
K. Murata, A. Harrison, How to make Japanese Management methods work in the west, 1st edn. (Gower Publishing, Aldershot, 1993)
J.P. Womack, D.T. Jones, Lean Thinking: Banish waste and create wealth in your corporation, 2nd edn. (Simon & Schuster UK Ltd, 1998)
Boyle, T., Scherrer-Rathje, M., Stuart, I., Learning to be lean: the influence of external information sources in lean improvement, J. Manuf. Tech. Manag. 22, 587603 (2011) CrossRefGoogle Scholar
K. Durward, I.I. Sobek, A. Smalley, Understanding A3 Thinking. A critical component of Toyota’s PDCA management system, 1st edn. (Productivity Press, Boca Raton, 2008)
Furlan, A., Vinelli, A., Dal Pont, G., Complementarity and lean manufacturing bundles: an empirical analysis, Int. J. Oper. Prod. Manag. 31, 835850 (2011) CrossRefGoogle Scholar
Angelis, J., Conti, R., Cooper, C., Gill, C., Building a high-commitment lean culture, J. Manuf. Tech. Manag. 22, 569586 (2011) CrossRefGoogle Scholar
Hines, P., Rich, N., Hittmeyer, M., Competing against ignorance: advantage through knowledge, Int. J. Phys. Distrib. Logistics Manag. 28, 1843 (1998) CrossRefGoogle Scholar
Womack et al., The machine that changed the world: How lean production revolutionized the global car wars, 2nd edn. (Simon & Schuster, 2007)
Smart, A.P., Maull, R.S., Radnor, S.J., Housel, T.J., An approach for identifying value in business processes, J. Knowledge Manag. 7, 4961 (2003) CrossRefGoogle Scholar
Sim, L.K., Rogers, W.J., Implementing lean production systems: barriers to change, Manag. Res. News 32, 3749 (2009) CrossRefGoogle Scholar
Braunscheidel, M., Hamister, J., Suresh, N., Star, H., An institutional theory perspective on Six Sigma adoption, Int. J. Oper. Prod. Manag. 31, 423451 (2011) CrossRefGoogle Scholar
T. Ohno, Toyota Production System: Beyond Large-scale Production, English translation (Maple-Vail Book Manufacturing Group, 1988)
J.K. Like, The Toyota Way: 14 Management Principles from the world’s greatest manufacturer (McGraw-Hill Education, 2004)
Hines, P., Rich, N., The seven value stream mapping tools, Int. J. Oper. Prod. Manag. 17, 4664 (1997) CrossRefGoogle Scholar
Sanchez, A.M., Perez, M.P., Lean indicators and manufacturing strategies, Int. J. Oper. Prod. Manag. 21, 14331451 (2001) CrossRefGoogle Scholar
Hines, P., Rich, N., Esain, A., Value stream mapping: A distribution industry application, Benchmarking: An Int. J. 6, 6077 (1999) CrossRefGoogle Scholar
Radnor, Z., Barnes, D., Historical analysis of performance measurement and management in operations management, Int. J. Prod. Performance Manag. 56, 384396 (2007) CrossRefGoogle Scholar
C. Jimmerson, A3 Problem Solving for Healthcare (Healthcare Performance Press, New York, 2007)
Radnor, Z., Muddled, massaging, manoeuvring or manipulated? Int. J. Prod. Performance Manag. 57, 316328 (2008) CrossRefGoogle Scholar
Palmer, E., Parker, D., Understanding performance measurement systems using physical science uncertainty principles, Int. J. Oper. Prod. Manag. 21, 81999 (2001) CrossRefGoogle Scholar
E.W. Deming, Out of the Crisis (The MIT Press, London, 1982)
M. Walton, The Deming Management Method: The Complete Guide to Management, 2nd edn. (Dodd, Mead & Company Inc., 1992)
S. Shingo, Zero Quality Control: Source Inspection and the Poke-yoke System (Productivity, Inc., Cambridge, 1986)
D.K. Macbeth, Advanced Manufacturing. Strategy & Management (IFS Ltd., Bedford, 1989)
K. Stout, Quality Control in Automation (Kogan Page Ltd, London, 1985)
Pan, J.N., Determination of the optimal allocation of parameters for gauge repeatability and reproducibility study, Int. J. Qual. Reliab. Manag. 21, 672682 (2004) CrossRefGoogle Scholar
S. Rabinovich, Measurement Errors: Theory and Practice (AIP Press, Woodbury, NY, 1995)