Process variation, inherent in manufacturing, impacts efficiency and quality.
Common cause variation is predictable, while special cause is not.
Lean methods like Six Sigma aim to reduce variation, enhancing efficiency and competitiveness.
📌 Related videos
▶ Process Mapping
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✍ Here is the transcript of the video
Process variation refers to the fluctuation or inconsistency in the output of a manufacturing process.
It's a natural occurrence in any process, but in the context of industrial engineering and lean manufacturing, the goal is to minimize this variation as much as possible to improve efficiency, quality, and predictability.
▶ 2 Types of Process Variation
There are two types of process variation: common cause and special cause.
* Common cause variation is inherent in the process; it's predictable and forms a consistent pattern.
This could be due to factors like slight differences in raw materials, minor fluctuations in machine performance, or environmental conditions like temperature and humidity.
* Special cause variation, on the other hand, is unpredictable and does not form a consistent pattern.
It's usually due to specific, identifiable factors, such as a machine malfunction, a sudden change in raw material quality, or human error.
▶ Process Variation and Quality
Process variation can have significant impacts on the quality and efficiency of production.
High levels of variation can lead to defects, rework, and waste, all of which increase costs and delay delivery times. It can also make it harder to plan and manage production, as the output is less predictable.
▶ Process Variation Management
To manage process variation, industrial engineers use a variety of tools and techniques, such as statistical process control, Six Sigma, and lean manufacturing principles.
These approaches aim to identify, reduce, and control variation, leading to more stable and efficient processes.
▶ Conclusions
In the context of lean manufacturing, process variation is seen as a form of waste.
By reducing variation, you can move closer to the ideal of one-piece flow, where each item moves through the production process without delays or rework.
This can significantly improve efficiency and reduce costs, making your operations more competitive and sustainable.
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