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Qualica Lean Six Sigma

Fighting Muda, Mura and Muri

When Taiichi Ohno and Shigeo Shingo looked for improvement opportunities in Toyota's factories many years ago, they identified "three wastes" - Muda, Mura and Muri, Japanese for waste, unevenness and overburdening. When they developed the Toyota Production System, their key goal was to avoid and fight Muda, Mura and Muri wherever possible.

Qualica's Lean Six Sigma Strategy against Muda addresses the 7 types of waste:

  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Overproduction
  • Overprocessing
  • Defects

Qualica extends the concept of Lean Six Sigma to the entire value stream: An optimized factory can only operate at full potential if it is aligned with Lean administrative, R&D and support processes. Qualica's consultants will instruct operators, supervisors and managers to identify and eliminate non value added activities. Qualica Lean Six Sigma methodology includes Value Stream Design, 5s, Implementation of Visual Management systems and Kaizen. Lean analysis is augmented by data-driven baselining of processes to identify true bottlenecks. 

In any environment - from financial services to production - Qualica consultants will work hands-on with the people actually involved in running the process. We will actively help collect and analyze data, implement 5s, and put up visual planning systems to make processes leaner. Through practical involvement, this will encourage employees to continuously improve processes and roll out Lean Six Sigma to the entire organization.

Lean Pharma, Chemical, Process Industry

In Pharmaceutical, Chemical and Process Industry, Lean principles successfully adopted by piece-part manufacturing industry around the world can not always be implemented 1:1. In batch processes and continuous flow some Lean concepts become less, others more important. In regulated industries like pharma, GMP requirements impose additional restrictions.

Qualica's consultants are experienced in process industries ranging from pharmaceutical production (API to tabletting), Lean QA/QC, to continuous process industries like steel.

Lean Innovation

The Toyota Production System would not be as efficient as it is, would Toyota not have expanded Lean thinking to its new product development organization. Lean Innovation utilizes Design For Lean Six Sigma tools and best practices to implement a development process avoiding waste, minimizing work in process, and thus resulting in faster time to market and more, successful products developed with the same number of resources.

Find out more about Qualica's approach to Lean Innovation...


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