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Lean Manufacturing or Six Sigma: Understanding Two Paths of Process Perfection
Mechanical engineering updates, hot jobs, best video games for engineers, and our Engineer of the Week is...
Shubhangi Dua
February 08, 2024
Manufacturing processes usually involve a complex set of activities full of opportunities for improvement. Organizations often turn to methodologies like Lean Manufacturing and Six Sigma when optimizing manufacturing efficiency. Today, in the Mechanical newsletter, we will understand the fundamental differences and applications of these methods.
Hold tight as we take a peak into China’s superfast hyperloop train, luxury submarines, and one of the seven wonders of the ancient world. Mechanical takes you on a thrilling journey through cutting-edge innovations, exceptional engineering insights, and timeless marvels that continue to inspire us today.
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INDUSTRY UPDATES
🛥️ Migaloo to set sail 'world’s first $3 Billion luxury super submarine'
The European private submersible yacht firm has managed to combine superyacht luxury with submarine stealth.
🚝 China's new maglev hyperloop train project crosses 387mph in testing
The “high-speed flier” broke records on a 1.2-mile test line with stable levitation, surpassing previous records.
🤖 Researchers design robots to maintain resilient deep-space habitats
Harvard Engineers develop robots to repair or replace damaged components in deep space habitats.
🐻❄️ Engineers spot polar Bear dens via radar
Researchers use an aircraft's synthetic aperture radar system to detect polar bear dens.
SPOTLIGHT
Spotlight - Lean vs Six Sigma: What’s the Difference & Use Cases
Lean Manufacturing and Sigma Six are the two most preferable approaches to process optimization and waste reduction. While both aim to improve efficiency and quality within manufacturing processes, today, we will explore the differences that set them apart today.
What is Lean Manufacturing?
A highly systematic approach founded by Henry Ford and later improved by Toyota, Lean Manufacturing is about minimizing waste and maximizing customer value. This approach emphasizes workflow analysis and eliminating non-value-adding activities across the organization.
The lean approach identifies seven common waste areas and aims to optimize flow, reduce cycle time, and enhance product quality by addressing them. The purpose is to create a lean production process that enables maximum value with minimal resources.
Six Sigma
Motorola engineer Bill Smith introduced Six Sigma in the 1980s. This method focuses more on achieving near-perfect results by minimizing defects and variations in production to enhance. A defect is defined as anything that fails to meet customer expectations, due to which variations are reduced to maintain consistency and improve customer experience. Six Sigma works on the DMAIC (Define, Measure, Analyze, Improve, Control) principle. This data-driven approach involves robust analytical and statistical techniques to solve problems and enhance the process. Six Sigma is a more customer-centric approach meant to identify the root cause of a defect and mold the process for cost reduction and consistent results.
Key Differences:
Objective
Lean Manufacturing aims to optimize manufacturing flow and eliminate unnecessary activities to reduce waste.
Six Sigma minimizes defects and variations to maintain consistent results and improve customer satisfaction.
Method of Identification
Lean identifies waste in the production process and focuses on improving workflow.
Six Sigma identifies variations and defects through statistical analysis.
Approach
Lean emphasizes process analysis and continuous optimization.
Six Sigma uses statistical tools and the DMAIC methodology for data-driven problem-solving.
Focus:
Lean targets non-value-added activities and inefficiencies in workflow
Six Sigma targets variations and defects to enhance process quality.
If you’d like to learn more about Six Sigma, we’ve covered the topic in depth here.
 | Engineer of the WEEK1765 - 1825Eli Whitney  Teacher |
Widely known as the inventor of the Cotton Gin, engineer and teacher Eli Whitney is deemed the father of American technology. His invention did make cotton extremely profitable but regrettably also helped keep slavery going for decades after his demise in 1825. While his better-known invention did not earn him much fortune, It was as a manufacturer of muskets that made Whitney rich. He pioneered the "American system" of mass production, which involved machine-made, interchangeable parts that had a lasting impact on the manufacturing landscape. His genius manifested through his inventive tools, machines, and ideas, and he played a vital role in bringing prosperity to both the Southern and Northern states of America. | |
BOOK RECOMMENDATIONS
💨 The Boy Who Harnessed the Wind by William Kamkwamba and Bryan Mealer
The inspiring true story of a young boy in Malawi who saves his village from starvation. With limited resources, the protagonist builds a windmill to generate electricity for his village.
⚙️ The Evolution of Useful Things by Henry Petroski
Engineer Henry Petroski takes his readers through the history and mechanisms behind everyday objects. He reveals the thought processes and design principles of these objects most engagingly.
❖ Stuff Matters: Exploring the Marvelous Materials That Shape Our Man-Made World by Mark Miodownik
In this book, famous Material Scientist Marik Miodownik examines the remarkable properties of common materials and their impact on society.
⏱️ Longitude: The True Story of a Lone Genius Who Solved the Greatest Scientific Problem of His Time by Dava Sobel
This book sheds light on the story of an 18th-century English clockmaker, John Harrison. The story is about his 40-year quest to build the perfect timekeeper.
Here are the EVENTS you'll love:
Precision in Motion: Navigating the
World of Mechanical Engineering Innovations
Aug. 22 • 9 a.m. PT / noon ET
Designing Tomorrow: Insights for Engineers
Aug. 23 • 9 a.m. PT / noon ET
Merging Mechanics and Ingenuity: Webinar Series for
Mechanical Engineers
Aug. 22 • 10 a.m. PT / 1 p.m. ET
Spider-like robotic AI arms can be attached to and controlled by humans Remember Doctor Octopus and his robotic tentacles in the 2004 movie Spider-Man 2? A Japanese robotics company has engineered.
Spider-like robotic AI arms can be attached to and controlled by humans Remember Doctor Octopus and his robotic tentacles in the 2004 movie Spider-Man 2? A Japanese robotics company has engineered.
Spider-like robotic AI arms can be attached to and controlled by humans Remember Doctor Octopus and his robotic tentacles in the 2004 movie Spider-Man 2? A Japanese robotics company has engineered.
 | Written by KASHYAP VYAS Science & Technology Writer
|
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