Final answer:
The mid-1990s strike at a GM supplier exemplifies the weaknesses of just-in-time manufacturing in relation to lean production. Six Sigma can be leveraged to minimize these risks, enhancing supply chain resilience and operational efficiency.
Step-by-step explanation:
When examining recent incidents in the manufacturing sector in relation to lean production, a noteworthy case is the impact of just-in-time (JIT) manufacturing on General Motors (GM) and its supply chain. A prime example of the risks associated with JIT is the mid-1990s strike at a GM parts supplier in Dayton, Ohio. This strike halted production not only at the main assembly plant but across the entire network of suppliers due to the lack of buffer stock, showcasing a failure in lead time flexibility.
The root cause of this issue lies in the reliance on JIT and the minimal inventory practices that leave no room for disruptions. To address such vulnerabilities, Six Sigma tools can be used in lean production to improve process efficiency and reduce defects. For example, using DMAIC (Define, Measure, Analyze, Improve, Control) can help identify problems more objectively and develop solutions to minimize the risk of disruption.
Implementing Six Sigma tools in GM's JIT strategy would entail rigorous data collection and analysis, leading to more resilient supply chain practices. These improvements could result in reduced waste, lower defect rates, and greater flexibility in the face of unforeseen disruptions. Such changes are expected to positively impact lead times, operational efficiency, and labor relations, thereby strengthening the overall competitive stance of the company.