Lean Six Sigma — Lean module

Lean Six Sigma in the ERP: SMED, 5S and Kaizen tied to your workstations

The AVIA ERP Lean module gives a tool for each approach — SMED study, 5S audit, Kaizen projects, improvement plan — and ties them to the ERP’s workstations, nonconformities and manufacturing orders.

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SMED study

Lean Six Sigma — Lean module

On a workstation chosen from the list of workstations, each operation is described, classed internal or external with its duration, then reclassed (internal, external or eliminated) with its target duration and the improvement action.

Status
Available
Module
Lean Six Sigma

The module’s tools

  • SMED study and series changeover checklist
  • 25-criterion 5S audit
  • Kaizen projects and company improvement plan

Short answer

Lean aims to remove waste, Six Sigma to reduce variation: two methods for two problems. In AVIA ERP, the Lean module implements the first family — SMED study of series changeovers, 5S audit, Kaizen projects — and an improvement plan reads ERP data (manufacturing orders, SMED studies, 5S audits, nonconformities, OEE) to rank findings by severity. On the Six Sigma side, the product offers a DMAIC guide and, in the Quality module, OEE and statistical process control; it does not compute a sigma level. The Lean module is included in the Enterprise pack.

What the module contains

Every tool exists in the product. Those whose scope is narrower than their name are marked “Partial” and explained.

  • Available

    SMED study

    On a workstation chosen from the list of workstations, each operation is described, classed internal or external with its duration, then reclassed (internal, external or eliminated) with its target duration and the improvement action. The screen computes the eliminated time, the internal time before and after, and the reduction against the target.

  • Available

    Series changeover checklist

    A changeover preparation, attached to a planned or in-progress manufacturing order: five points marked OK or KO, with comment — safety, supply, staffing, equipment, documentation — and a validation date.

  • Available

    5S audit

    Twenty-five criteria, five per S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke), scored 1 to 4 with comment, on a workstation linked to the workstation list. Score per S and total score, compliant status or not, filterable list. An action plan is proposed by the AI from the poorly scored criteria.

  • Available

    Kaizen projects

    One sheet per project: type (Kaizen, Lean, Six Sigma, SMED, quality, safety), targeted process, priority, current and target value, estimated gain, target date. A Kaizen board sorts projects into four columns by status.

  • Available

    Company improvement plan

    It reads items, manufacturing orders, purchase requests, SMED studies, 5S audits, nonconformities, OEE, machine load and projects, then produces a maturity score and findings ranked by severity, with the link to the relevant screen and the associated method (Lean, Six Sigma, SMED, 5S).

  • Partial

    Six Sigma: guided DMAIC, measurement through Quality

    The DMAIC tab is a guide to the five phases with their tasks, not editable: phases are not filled in on the screen. Measurement relies on the Quality module: OEE per workstation (availability, performance, quality) and SPC control charts with Cp and Cpk, reading existing measurements. No sigma level or DPMO calculation.

What the module does not cover

To decide whether it is enough for your approach, here are the tools you will not find in it.

  • No value stream mapping (VSM) and no A3 sheet: no screen is dedicated to them.
  • No Pareto chart as a quality tool. Stock ABC analysis exists, but it is a different tool.
  • No TPM: maintenance is managed in the Maintenance module, without autonomous maintenance or operator checklists.
  • The manufacturing-order board by status is not a card-based replenishment kanban.
  • OEE does not break losses down by cause (breakdowns, setups, micro-stops): stops are not recorded.
  • Root causes (Ishikawa, 5 whys) are generated by the AI assistant from a nonconformity; they are not a field kept in the record.

How it is deployed

The Lean module is included in the Enterprise pack (deployment in 6 to 12 weeks). OEE and SPC belong to the Quality module, present from the Professionnel pack (2 to 4 weeks). SMED studies and 5S audits build on the workstations already created in the ERP.

Going further

Two method guides to choose between Lean and Six Sigma and to cost a tooling changeover, a guide on quality audits, sectors where shop-floor discipline weighs, and neighbouring pages.

Guides

Sectors

Related pages

Frequently asked questions

What is the difference between Lean and Six Sigma?

Lean tackles waste and lead time; Six Sigma tackles variation and the dispersion of results. The guide “Lean or Six Sigma” helps work out which of the two problems you have before applying a remedy.

What is a SMED study in AVIA ERP?

A study tied to a workstation: each operation of a changeover is classed internal or external, with its current duration, its improved duration and the improvement action. The screen computes the eliminated time and the reduction against the target.

How does the 5S audit work?

Twenty-five criteria, five per S, scored 1 to 4 with comment, for a score per S and a total score. The lowest-scored criteria are the basis for an action plan proposed by the AI.

Does the module compute a sigma level?

No. The product offers a DMAIC guide of the five phases, and the Quality module provides OEE per workstation and control charts with Cp and Cpk; it computes neither a sigma level nor DPMO.

Which pack includes the Lean module?

The Enterprise pack, whose deployment takes 6 to 12 weeks. OEE and SPC are in the Quality module, present from the Professionnel pack.

Let’s look at one of your changeovers or workstations. Forty-five minutes, one real process, a written summary.

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