Continuous improvement in the industry: 4 models to implement

Mejora continua en la industria y 4 modelos para implementarla.

Engineering

Autor

October 6, 2023

5 min

Continuous improvement is a philosophy that aims to positively impact our lives and the activities we carry out. This gives us a differentiator in facing the challenges of today’s world, in which it is no longer enough to learn only one thing at a time and remain static, but it is vital to improve, detect opportunities, and always continue looking forward.

As a management methodology, it applies to any area seeking notable performance and greater efficiency. The continuous improvement in the industry can be applied in delicate operations, such as manufacturing, to prevent failures and minimize productivity losses in productivity. By carrying out continuous improvement, it is possible to continually review and monitor each system’s component, and thus, detect opportunities.

In the following paragraphs, we will review what continuous improvement is, its bases are, 4 models to apply daily, and how it can improve the entire project’s processes.

Index

What is continuous improvement?

Continuous improvement is an approach towards incremental perfection through monitoring the activities carried out. “What does continuous improvement mean in an organization?” It refers to the principle of quality management to obtain advantages and benefits that are reflected in greater competitiveness.

So, each effort results in changes that positively evolve activities if a review cycle is carried out.

Suppose you’re asking for an example for continuous improvement. In that case, you can see it in a process or production line. Some objectives are to reduce costs, increase process safety, implement, or even develop new technologies. Also, optimize both human resources, among many other benefits.

To carry out continuous improvement, you must be clear about complying with international standards, such as ISO 9001, which focuses on management to achieve maximum quality. But like everything that has long-term results, applying this management must become more than just sporadic actions, it must become a life philosophy.

Now that we know our main topic’s basis and definition, it is time to review the different paths to maximum quality. Next, we will discuss 4 models for process improvement, which have been created for each activity to be increasingly profitable, high quality, and competitive in the sector.

Get to know how to achieve the continuous improvement in the industry.

Continuous improvement models

There is a diversity of methods to make changes searching benefits for a project improvement, such as Deming, Six Sigma, Lean and Kaizen. All these methodologies are characterized by increasing collaborators’ interests in teamwork, monitoring, work systematization, and variant reduction, defects, or processes out of sight. Let’s give them a quick review.

Deming

What is the Deming cycle? As one of the approaches that facilitate continuous improvement, it is very popular due to its clear steps. This model is made by 4 phases that, according to the theory, ensure quality thanks to: Plan – Do – Review – Act, ending up in a cycle that we will need to repeat over time.

One of the competitive advantages is the promotion of a better routine in the entire work team. This positively influences the entire project management and makes a solid base for developing new products or tests. This model works like a cycle; meaning that it must be done constantly.

The following points, are in fact, the steps:

Plan: Identify an opportunity and plan for a change

The system’s organization is analyzed to find defects. At this stage, we can ask questions about the project’s future, how to meet the expectations and how the objectives are met. That way, defining goals, identifying errors or finding opportunities is simpler.

It is recommended to apply group segmentation in cells, according to specific tasks and functions; this will help us to make supervision easier.

Do: Implement change on a small scale

Logically, the next step is to do. It is about applying the plan made previously, and it may take considerable time to do so. The changes must be applied in a controlled and supervised manner in each group. The review of every process is vital, which do not, and makes a testing that includes the necessary documentation as evidence.

Review: Analyze the results

Verify time has arrived, and in this stage, we review and study the indicators or insights that we can obtain from the figures. The most important thing is to detect which of all the implementations is the trigger for continuous improvement and officially integrate it into the processes. This gives an advantage against future errors and allows the positive impact to be seen in each cycle.

The most significant thing is to detect which of all the implementations triggers continuous improvement and officially integrate it into the process. This gives us an advantage against future errors and allows the positive impact to be seen in each cycle.

Act: Make all the changes happen

If the change succeeds, it can be extended to the entire operation, not just in the work cell. This implementation needs to be scaled and continuous. If it doesn’t work, you can re-start again. And so, the cycle begins again, including new knowledge and, of course, benefits.

Deming cycle for continuous improvement.

Six Sigma methodology in continuous improvement

Six Sigma is one of the most helpful improvement techniques for organizations, industries, or companies. Its application consists in creating uniformity in actions to reduce variants in the result. With this model, the objective is to minimize defects and optimize every part.

And, also, this methodology is based on a philosophy as well, that indicates that everything can be defined, measured, analyzed, improved, and controlled.

Furthermore, it maintains that there are inputs and outputs, that is, acts and effects in every project.

Six Sigma for continuous improvement is fundamental by a way of think, thinking: the more control there is over the elements, or inputs; the more control we can have over the output. We can review how this methodology works by understanding basic concepts.

Sigma is a Greek letter (Σ, σ, ς); in statistics it indicates the standard deviation or typical deviation of a group of numbers in dispersion. This letter points out that the smaller the dispersion in data, the lower the standard deviation, and then the process will be better measured.
After this, there is the “sigma level” which refers to the number of deviations that fit within the limits of a process. There is a goal to achieve with this model, in all there must be 6 sigma levels with a performance of 99.9997%.

Applying this continuous improvement method has some benefits, such as:

Profitability of industrial processes.
Increase in the quality of the final product.
Reduction of resource waste.
Lower cost in production line components.
Results in less time compared to other methodologies.
Risk detection before they become a problem.

Like any other methodology, it includes steps to follow, and we will describe them below.

Definition: In this phase, it is essential to establish all elements clearly and precisely, including goals, opportunities, requirements, next steps, and metrics.
Measurement: Compilation of data for subsequent analysis and, if required, adjustment of the strategy.
Analysis: A thorough review of the results to identify not only minor problems, but also the root cause of them to improve indicators.
Improvement: Implementation of solutions to identified issues. It is recommended to conduct tests to evaluate its feasibility before definitively applying the improvements.
Control: Supervision of the implementation of solutions is a crucial aspect in this methodology, since solutions without adequate monitoring can lead to new errors

This is Six Sigma method for continous improvement.

Lean methodology

Lean method, also known as Lean Thinking or simply Lean, is a management and production approach that originated in Japan, particularly Toyota, in the 1950s. The goal is to eliminate waste in business processes to improve efficiency, quality, and speed of delivery. All of these happen while the collaborators are involved in this new philosophy.

Its name is due to the idea of doing more with less, that is; remain lean, reducing any activity that does not add final value.

The operation under this methodology is based on several key principles that mark the following phases:

Value Stream Mapping: After grasping the concept of value, the methodology involves mapping out all the processes required to deliver it. This graphic representation helps in planning, how to create, deliver, and minimize resource wastage.
Waste Elimination: This phase is about the eight core concepts that constitute the foundation for waste reduction: overproduction, waiting time, unnecessary transportation, excessive processing, unnecessary inventory, unrequired movement, defects, and underutilization of human talent. The aim is to avoid or minimize each of these elements to make a significant impact.
Creating Flow: Once waste is identified and removed, the focus shifts to establishing continuous and efficient workflows to ensure products move through the process without interruptions.
Production on Demand: This principle emphasizes producing only what is demanded, as excess production leads to waste and the inefficient use of resources. The Lean methodology encourages production on demand.
Continuous Improvement (Kaizen): Continuous improvement involves efforts at all organizational or projects levels. It requires each team member's genuine commitment to resolving issues continually, making incremental changes, and then building upon them. This concept is closely connected to the subsequent methodology discussed in this section.
Employee Empowerment: The core of any operation lies in its team members, as their active involvement in decision-making and the implementation of improvements is pivotal. Recognizing those who possess in-depth knowledge of the processes and can contribute to efficiency enhancements is crucial.

Lean methodology for an improve in your processes.

The Lean methodology, which emphasizes waste reduction, enhanced efficiency, and improved quality, while fostering a culture of continuous improvement, is applicable across various industries and processes. From manufacturing to services, its objective is to achieve quicker and more effective outcomes while meeting customer requirements.

Kaizen

Now, let's delve into the methodology closely linked to Lean: Kaizen. Like its predecessor, Kaizen is a valuable approach for enhancing process quality.

What is Kaizen? It serves as a business management system comprising five actions aimed at enhancing operations in every facet of an organization. Kaizen strives for excellence and impeccable performance, establishing itself as a cultural philosophy due to its underlying principles.

Hailing from Japan, its name derives from the kanji "kai," meaning change, and "zen," signifying good. Collaboration is at its core, with the fundamental belief that training staff to make minor adjustments to their tasks can, over time, lead to significant positive changes.

What is the definition of continuous improvement in the workplace? For instance, the improvement can initiate change through small actions such as "tidy your workspace upon arrival and departure," instead of relying on the cleaning team for this task. This is the basis for the deeply ingrained culture of continuous improvement in Asian countries.

This is also how continuous improvement in the industry works when combined with other minor efforts like cleaning up unnecessary computer files or dedicating a few minutes each day to software maintenance, you'll notice a decrease in errors, subsequently boosting productivity.

**Organizations and industries that embrace the Kaizen philosophy gather several benefits, including: **

Resource Conservation: Resources are conserved by taking better care of material resources and providing proper maintenance.
Mindset Transformation: Employees undergo a mindset shift, leading to a substantial increase in productivity and engagement.
Improved Work Environment: The work environment is enhanced, increasing employee satisfaction.
Leadership Development: Kaizen increases the number of leaders within the organization.
Values Promotion: Kaizen promotes values among all team members.

Continuous improvement with the 5s from Kaizen.

The 5S of Kaizen

How is the Kaizen method implemented? Are there guidelines? Yes, to facilitate its adoption, there is a concept known as the “5S of Kaizen” which, consists of 5 actions:

Seiri (Sort): Also known as eliminating the unnecessary, this involves determining which elements are essential and which are not, both in workspaces and production plants. This is because not everything in space is useful and conducive to daily operations, such as accumulating material or digital resources that hinder production.
Seiton (Straighten): Once the useful and non-useful classification has been done, it’s necessary to organize them. To achieve this more effectively, you can ask questions about how to use these resources best, how to arrange them, where to place those used frequently, or whether recycling is a better option.
Seiso (Shine): This is all about keeping every space clean and shiny, to make the spaces functional and pleasant for everyone who works there and extend the lifespan of the machinery and devices. An advantage is the reduction of accidents.
Seiketsu (Standardize): It’s a step in continuous improvement that involves maintaining the standards applied in the first three S’s. This ensures that everything continues to work as it has, possibly even better.
Sitsike (Sustain): Large-scale change is achieved through discipline;, it’s necessary to adopt this as a way of living, a philosophy and bring it to daily work, contributing to the operation’s success and overall, harmony in the workspace.

Continuous improvement has an impact in every component of the system

The success of a process, project, or company is directly linked to the methodology adopted for execution. Planning for winning is essential to understanding the best steps toward an objective. When production adopts an approach focused on excellence or impeccability, there is less risk of making an error or seeing losses in the project.

The real impact will vary depending on the goal and areas involved. Still, in general, each of the reviewed methodologies aims to increase efficiency, quality, and customer satisfaction, which can be translated as benefits. The choice will depend on the short or long-term objectives and the company’s specific needs.

Continuous improvement benefits greatly all areas and processes carried out daily in a production plant or project. At Autmix Process, we can support you in optimizing operations to achieve the best performance and, outstanding final quality. Contact us.