Manufacturing organisations are continually looking for new and different approaches to quality and efficiency. In this blog, we’ll explore five common approaches: Quality by Design, Lean Manufacturing, Six Sigma, Total Quality Management and Kaizen.
The purpose of this blog is to give a brief overview, to look at the origins of these principles and provide readers with a general idea of each. Each one of these concepts could form the basis for a PhD and there will be many areas for further research.
In practice, it’s common to combine these approaches to create a tailored method for the needs of each organisation. We should also mention that at least one combination has already been formalised into a unique approach of its own: Lean Six Sigma. What links all these together is their intended outcome of improved quality and efficiency. The way they achieve that goal is widely different.
From Quality by Design, which addresses the start of the process by integrating quality into the earliest stages of product development, to Kaizen, which looks to make many small changes leading to continuous improvement and long-term gains in productivity and quality. Each methodology offers a unique set of tools and perspectives.
Quality by Design (QbD)
Quality by Design was probably first discussed by J.M. Juran in 1992. His book on the topic has gone into multiple editions and is still in print today. At its core, QbD is a proactive approach to quality management that emphasises the integration of quality into the earliest stages of product development. In doing that, it ensures that every following stage of the production process has the best possible chance of hitting the quality requirements.
With this approach, defects are discovered and mitigated before the products reach the end of the production line. Manufacturers will never find themselves in the situation of having to waste an entire batch of product. This approach means understanding the product and process thoroughly, identifying potential risks and designing controls to mitigate them.
QbD is particularly common in high-tech industries and pharmaceuticals, where it helps ensure products meet stringent regulatory standards. By focusing on design and development, QbD reduces the likelihood of defects and enhances overall product quality.
Lean Manufacturing
Lean Manufacturing is perhaps one of the oldest methodologies here with its origins in the Toyota production system of the 1950s. It’s a methodology that aims to maximise value by minimising waste throughout the product lifecycle. Lean manufacturing focuses on identifying and eliminating activities and operations that don’t add value to the end user. In this way, organisations can focus on the things that really matter, improving quality, efficiency and reducing costs.
The core principles of lean include value stream mapping, continuous flow, pull systems and continuous improvement. By streamlining processes and concentrating on efficiency, lean manufacturing helps organisations deliver high-quality products more quickly and cost-effectively.
Six Sigma
Six Sigma is a data-driven methodology that was first developed by an engineer called Bill Smith at Motorola in the 1980s. This approach improves quality by using statistical analysis to identify and eliminate defects in a process. It uses a set of mathematical tools and techniques to analyse data and identify root causes of variabilities within the production lifecycle. The goal of Six Sigma is to achieve no more than 3.4 defects per million opportunities – near perfection!
Six Sigma projects typically follow the DMAIC (Define, Measure, Analyze, Improve, Control) framework, which guides teams through a structured problem-solving process. By reducing variability and improving process capability, Six Sigma enhances product quality and customer satisfaction.
Total Quality Management (TQM)
Total Quality Management was one of the original approaches to quality. It’s credited with having laid the foundations for quality management as we know it today.
These days, it’s been almost entirely overshadowed by other approaches. But at its heart, the central concepts hold true. It was designed as a comprehensive method to long-term success through customer satisfaction. TQM involves the participation of all members and departments of an organisation in improving processes, products and services. It was one of the very first approaches to quality that recognised the importance of organisational culture within the manufacturing sector. It recognised that supporting functions like accounting, marketing and HR all play a role in quality and must also actively manage quality.
The principles of TQM include customer focus, continuous improvement, employee involvement and process control.
Kaizen
Kaizen is a Japanese term meaning literally “good change”. Perhaps a more accurate translation might be “continuous improvement.”
Kaizen is an approach to quality with a basis in Eastern philosophy. Instead of starting with a holistic view and then zooming into individual processes, it focuses often on small, incremental changes. This gradually improves wider efficiency and quality overall. Kaizen involves employees at all levels of an organisation, encouraging them to identify areas for improvement and implement changes wherever they might come across them. Even something small like keeping a tidy and organised workspace is considered an important part of Kaizen.
The Kaizen approach emphasises teamwork, personal discipline, improved morale and quality feedback cycles. The idea is that lots of small improvements add up to one big improvement and in this way, organisations can achieve significant long-term gains in productivity and quality. Kaizen encourages constant learning and adaptation, ensuring that businesses remain competitive and responsive to change.
These methodologies each offer unique approaches to enhancing quality and efficiency, but they share common goals. That’s things like improving processes, reducing waste and delivering greater value to customers.
By understanding and implementing these principles, organisations can build a foundation for sustainable success and continuous improvement. Whether you’re just starting out or looking to refine your existing practices, these methodologies provide valuable tools to help you achieve your quality and efficiency objectives
