Lean Six Sigma: Why did we abandon the “Just in time” principle?

Lean Six Sigma is a concept that is known worldwide for its ability to streamline production processes, reduce waste and improve quality. At Brione Oy, as an expert in the manufacture of sheet metal products, we have implemented the principles of the Lean Six Sigma concept. Our expertise was confirmed in the fall of 2023 when our CEO Tero Niemelä received Lean Six Sigma - black belt certification. Dear Tero!

In accordance with the concept, we strive to continuously optimize our operations and provide our customers with the best possible quality. However, we have noticed that the implementation of Lean Six Sigma also has its own problems. People are not robots, and people may not always be able to implement Lean principles.

Everything is always late - this is what we are fighting against

Our Lean Six Sigma Black Belt certified worker has brought significant expertise and insight to our company with his skills. Tero regularly reminds us of our new internal motto: “All the unnecessary stuff is gone”.
One of the key ideas of Lean Six Sigma is that production is scheduled so that finished products remain in inventory for as little time as possible. The product should be finished close to the moment it is needed. This idea is the starting point of many industrial companies.

Everything is always late - this is what we are fighting against

Over the years, we have learned that companies around the world are late. There are different reasons for this, but this is how things seem to be. This leads to short inventory times. But due to lateness, customer satisfaction is low and employee stress levels are high because there is always a rush.

Why did we abandon the “Just in time” principle?

At Brione, we have taken it upon ourselves to be truly on time with our production. This means that we had to abandon the idea of ​​short storage times and the “just in time” principle. We don’t want products to be ready just in time, but well in advance. We try to keep a constant buffer in our production so that there is no rush and customer satisfaction doesn’t start to drop.

In practice, this means that we always strive to be one step ahead and produce products before the promised date. This not only reduces rush and stress among our employees, but also improves the customer experience by being able to deliver products on time or even early.

When we are a few days ahead in production, we tolerate things like sick leave and machine breakdowns well. They are not visible to customers because there is room for manoeuvre. Buffering really reduces stress when you are not constantly on the edge of a knife.

Case Example: Predictive Manufacturing Delivers Results

One of our customers ordered specially manufactured sheet metal products from us, the production of which was a complex and time-consuming process. The customer himself was under stress in his own production, and needed his products even earlier than the agreed time. The customer called and asked what model the products were, and whether they could be picked up at the agreed time.
The products were already in stock and the customer was able to pick up his products earlier than the agreed time.

Instead of strictly adhering to the "just in time" principle, we started production well in advance of the products being needed by the customer. This would allow us to have enough time to resolve any unexpected challenges in the production process without compromising the delivery schedule. As a result, the customer received their products even before the agreed schedule, and we avoided any additional stress and rush. Of course, we cannot always promise that products can be picked up before the agreed time. But we want to combat lateness by keeping a buffer in our own production.

Customer focus and quality go hand in hand

At Brione Oy, we believe that customer focus and high quality go hand in hand. While Lean Six Sigma offers valuable tools and techniques for improving production processes, we have chosen a path that combines these principles with a proactive and customer-oriented production strategy. This not only improves the well-being of our employees, but also ensures that our customers are satisfied with the products and service they receive.

If you would like to hear more about our practices or discuss how we can help your business, please get in touch.