An integrated application model and its implementation path of lean six sigma management and theory of constraints

Lean production, Six Sigma management and theory of constraints (TOC) is respectively a management method for manufacturing enterprises to achieve continuous improvement, and they have their own priorities and advantages. Integrating and applying the three in accordance with a certain procedure and a path can complement each other’s advantages, achieve breakthrough performances in reducing input costs, shortening production cycles, improving product quality and economic benefit, and so enhancing the competitiveness of enterprises. By analyzing their characteristics, this paper establishes an integrated application model of lean production, Six Sigma management and theory of constraints. The model is composed of target layer, function layer, process layer, and tool layer, and is implemented according to the process of project establishment, identification, improvement, control and circulation. This paper also proposes a universal implementation path with the major contradiction as entry point, which enables the model can be flexibly implemented according to the actual situation of the improvement project. The integrated application model was applied to the improvement of the lead-acid battery production process in CW Group. This resulted the average monthly output of batteries increased by 20%, and the return rate decreased by 15% year on year, which proved that the model is well operable and effective. © 2021, Chinese Society for Quality. All rights reserved.