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Category: Lean Six Sigma

Lean Six Sigma is more important than ever now

Posted on June 20, 2022 by Marbenz Antonio

Is Lean Six Sigma Still Relevant?

Why is Lean Six Sigma still a prominent business model in 2022?

First, the concept gained momentum in manufacturing as an effective way of eliminating waste and increasing quality; but, as Lean principles were more integrated into it, it was subsequently embraced in service sectors as well.

Today, as our world changes, it gets more competitive via innovation in products and services, platforms, and distribution systems. As a result, having a process in place to handle continual improvement is important.

Identifying a reason for Lean Six Sigma

What are the requirements for implementing Lean Six Sigma if an organization or individual professional has yet to dive into it?

Do you, for example, have dissatisfied customers? Do you have any product returns? Is it necessary to revise your outputs at the end of a manufacturing cycle?

These are just a few of the reasons why you should have a system in place to identify and address problems in your organization. Finally, you want to be able to provide customers with what they want at the lowest possible cost to you by employing an organized, methodical approach to issue resolution.

What is Lean Six Sigma and Why is it Important?

The five-step DMAIC method is the basis of the Lean Six Sigma strategy.

Define: that includes everything related to a process, beginning with what the customer wants, identifying what is important to quality, and defining each stage in the process, including who, what, which materials, and outputs.

Measure: what are the essential aspects throughout the journey, such as inventory, time, defect count, time spent on reworks, and so on?

Analyze: what does the data indicate? Where is the manufacturing process stalled? What elements may be affecting output quality?

Improve: How do you make things better? How can you improve process flow? How do you keep track of your inventory?

Control:  what procedures do you need in place to collect input and ensure that the fixes stay in place?

This procedure has a significant influence on quality and efficiency in a production context.

Siemens Automotive’s facility in Mexico, for example, assembles instrument panels for various automobiles and experienced a recurring fault on the production line. Circuit boards were failing when put in automobiles; utilizing Lean Six Sigma, we assisted them in identifying the issue: human mistake when installing a device, which caused the electronics to short.

Service businesses may increase quality while also reducing waste

Although many of the principles in Lean Six Sigma originated in the industrial industry, the methodologies are still applicable to service businesses, whether you work in accounting, mortgage processing, or coding. People in these surroundings must nevertheless go through many processes to carry out their duties.

For example, obtaining a mortgage loan necessitates an application, data collection (credit reports, etc.), and the generation of an acceptance letter for the consumer. In one real-world example, we worked with a mortgage firm to investigate their processes and cut the decision-making duration by three weeks, enhancing corporate productivity and producing happy consumers.

Even if the business does not produce a tangible product, there are possibilities to improve when there is a step-by-step process.

We’ve frequently questioned businesses, “Why do you do that?”

Rather than articulating client demands and doing everything possible to accommodate them, they prefer to remark, “We’ve been doing that forever.”

Lean Six Sigma as a Career Development Strategy

Lean Six Sigma is a skill set that is employed by virtually every big and mid-sized company in the world. Whatever role you work in now or in the future, you should be familiar with the methodology’s capabilities.

Combining a Lean Six Sigma certification with your degree or other academic studies might be the difference during a job interview for professionals earlier in their careers – having another aspect that makes you different/better than the other candidates.

Posted in Lean Six SigmaTagged Lean Six SigmaLeave a Comment on Lean Six Sigma is more important than ever now

Using Lean Tools to Solve Problems Effectively

Posted on May 17, 2022May 31, 2022 by Marbenz Antonio

Manufacturing Concepts and Principles - Kanban Zone

The combination of tools and strategies used to get to the bottom of a problem or issue in quality management is fundamentally part of Root Cause Analysis (RCA). Although some people like to solve problems in an ad hoc manner, RCA’s tools make the process more systematic and rigorous. This has been shown to provide outstanding outcomes.

Some of the tools help you to explore beyond the obvious to find the root reason. Others enable you to picture the situation in order to examine it from a new angle. And each tool is meant to assist you in identifying the true, hidden issue, which will prevent the problem or issue from recurring once it has been resolved.

This saves the team a significant amount of time. Patchwork is nothing more than constantly working on surface issues. If the root cause is not addressed, the problem will return, potentially getting worse with each occurrence. It also keeps the team from concentrating on the wrong problem or one that doesn’t need to be solved at all.

When it comes to RCA, clubs have a variety of options. The most prevalent ones are listed below.

Fishbone Diagram

The fishbone graphic is utilized when the problem at hand is complicated. It enables the team to divide potential causes into homogenous and sub-groups. It’s especially useful when the fundamental cause is obscured by a variety of superficial issues. The cause-and-effect diagram is another name for the diagram.

5 Why’s

The 5 Whys engages you in the role of a detective attempting to solve a mystery. It’s also not difficult because all you have to do is ask the question “Why?” ” five times – as a guideline, not a rigid rule – until the root problem is discovered. It works well on basic topics, thus it might not be the ideal choice if the quantitative analysis is required.

Pareto Chart

The effects noticed 80% of the time are due to 20% of the time causes. The essential premise of the Pareto Chart is this. This visualization tool gives a glimpse of typical faults so they may be quickly identified. It lists their causes in descending order to assist you to deal with them in the order of importance and urgency.

Failure Mode and Effect Analysis (FMEA)

When a system experiences a specific failure, the FMEA is the finest instrument for shedding light on it. The Failure Mode feature of the application allows you to brainstorm probable causes of system failure. These are the many types of failures. The impacts of each of the failure types discovered in the preceding stage are investigated further in Effects Analysis.

Conclusion

One of the numerous ways organizations accomplishes Six Sigma is to take Root Cause Analysis seriously. Because each problem is unique to the company, there is no one-size-fits-all approach to RCA. While additional tools may be used to perform RCA, these are the ones that successful companies employ on a regular basis. Each one has been proven time and time again to be helpful in permanently resolving difficulties and issues.

Posted in Lean Six Sigma, Six Sigma, UncategorizedTagged Lean Six Sigma, Six SigmaLeave a Comment on Using Lean Tools to Solve Problems Effectively

Lean Six Sigma Creates a Seamless Project Management

Posted on April 12, 2022May 31, 2022 by Marbenz Antonio

According to the Worldwide Project Management Survey Pulse, 12% of global firms were classified as under-performers in 2017. The list featured businesses from a wide range of industries, including the government, information technology, and financial services.

Project management was summarized in the survey. It demonstrated that 60 percent of the organization’s initiatives were completed on schedule and on budget. The absence of specified and measurable milestones and targets to monitor progress was also noted in the other initiatives.

Any project manager’s principal goal is to enhance productivity. They must be aware of the wide range of technologies, methods, and processes that might affect project delivery best practices.

Although current technology and procedures have shown a favorable upward trend in project delivery, there is still a growth gap that may be addressed by incorporating Lean Six Sigma into company operations.

Throughout the framework, the goal is to follow a repeatable process to achieve a good end and get a greater understanding of how integration may be accomplished.

What is Project Management?

Project management, according to PMI, is “the application of knowledge, skills, tools, and procedures to activities to achieve project requirements.”

Every project, from start to completion, needs a plan that describes how things will get started, how they will be created, and how they will be finished.

What is Lean Six Sigma?

Lean Six Sigma is a performance improvement strategy that focuses on a collaborative team effort to eliminate waste and reduce variance.

Minimizing variability, waste, and cycle time while increasing job uniformity and flow, improves customer satisfaction and outcomes.

The DMAIC (Define, Measure, Analyze, Improve, and Control) approach is often used to execute projects while using Lean Six Sigma.

DMAIC Improvement Process

The DMAIC model refers to problem-solving procedures that are used to continuously enhance an existing process. The technique is targeted at enhancing product/service quality.

DMAIC’s 5 phases are:

1. Define – Project teams create a high-level process map to define the demands of customers at this phase.

Tools used:

  • Project charter
  • Tree diagram
  • Value stream map
  • Relationship map
  • Stakeholder analysis
  • VOC (Voice of Customer)

2. Measures – The data-gathering plan is the focus of this stage. You develop and execute data that indicates how the process is doing, assisting in the delivery of variance, in this process.

Tools used:

  • Project charter
  • Data collection plan
  • Operational definitions
  • Check sheet

3. Analyze – Teams can calculate the financial rewards of fixing the challenge at this point.

Tools used:

  • Value stream map
  • Fishbone diagram
  • Value-added flow analysis
  • Gantt charts
  • Pareto charts
  • Root cause analysis
  • 5 why’s

4. Improve – This stage relies on the team’s inventiveness to solve the process challenge.

Tools used:

  • Value stream map
  • Brainstorming sessions
  • Benchmarking
  • Weighted criteria matrix
  • Impact/Effort matrix
  • Pilot checklist
  • Implementation plan

5. Control – This phase allows the team to report the new solution they’ve developed so that it can be passed on to the process owners.

Tools used:

  • Control plan (or a control chart)
  • Monitoring and response plan
  • Innovation transfer opportunities
  • Gallery walks
  • Documentation

Lean Six Sigma Integration in Project

DMAIC, a Six Sigma technique, provides a planned and disciplined approach to tackling business challenges. It pinpoints the source of faults in the business process, ensuring high quality throughout the project lifetime. Cross-functional teams are frequently used in Lean Six Sigma projects. The technique, on the other hand, does not explicitly handle project management.

Throughout the project management process, a variety of Lean Six Sigma approaches are applied. Project managers employ work breakdown analysis, schedule development, risk analysis, scope definition, status reporting, and cost budgeting to plan, execute, control, and conclude projects.

These approaches enable project managers to make smart and informed decisions as they progress from phase to phase throughout the project lifecycle. Project management and Six Sigma technologies may be used to plan, act, do, and check a process improvement project throughout the lifespan. In addition, approaches and procedures can be combined to improve the process.

The Advantages of Lean in Projects

Decision Making – Every defect/error has a data-based evidence approach in every Six Sigma technique. This procedure is more accurate than any other way.

Time-Saving – The advice of a Lean Six Sigma specialist at the start of each project defines the scope and deliverables precisely, as well as the efficient use of resources.

Cost Saving – Cost savings are a direct result of implementing Lean Six Sigma because the methodology’s primary goal is to minimize mistakes and defects.

Increase in Productivity – Because every member of the team is committed to the Lean Six Sigma methodology, productivity doubles, freeing up resources for other modules.

Conclusion

To acquire a more complete insight into the total process, the Lean Six Sigma methodology may be combined with project management procedures. Lean Six Sigma improves the capacity of businesses that exclusively utilize project management to make decisions based on evidence-based data and aspects that are important to quality and end-users.

Posted in Lean Six Sigma, Six SigmaTagged Lean Six Sigma, Six SigmaLeave a Comment on Lean Six Sigma Creates a Seamless Project Management

Are Lean vs. Six Sigma vs. Lean Six Sigma Different, Similar, or Compatible?

Posted on March 15, 2022 by Marbenz Antonio

There’s more at stake here than a misunderstanding and a headache. Misunderstandings regarding Six Sigma, Lean, and Lean Six Sigma sometimes lead to individuals or entire companies enrolling in training that falls short of their expectations. Let’s clarify the aims of each of these approaches, as well as their similarities and differences.

Six Sigma stands for “Efficiency First.”

Six Sigma is based on the examination of cause and effect, which leads to enhanced process quality by reducing process variance. Processes become more predictable and controlled, in other words.

Six Sigma has its origins in statistical methodologies from the early European industrial age in the 1700s, although it is most widely identified with Motorola in the 1980s in the United States. New product creation, process improvement, and customer satisfaction are just a few of the sectors and corporate processes that benefit from the business improvement technique.

Six Sigma is used to improve not only individual goods and processes but also whole companies. The technique not only aids in achieving the results that all organizations seek (such as increased revenue and client retention), but it also aids in instilling a culture of productivity, efficiency, and engagement.

Lean: Value Add Only

In manufacturing, service delivery, and general business operations, Lean focuses on identifying and eliminating all types of waste. Lean works to eliminate procedures that do not add direct value to the product or service at hand, and it is used to optimize production and administrative operations.

Check out the 7 Wastes of Lean for a better understanding of the kind of activities that are avoided.

  1. Transportation
  2. Inventory
  3. Motion
  4. Waiting
  5. Defects
  6. Overproduction
  7. Overprocessing

When properly applied, the technique produces a clean, efficient process that adds value to the end-user. Lean companies concentrate on eliminating non-value-added activities from individual processes and the entire business. What’s the result? The highest level of operational excellence.

The Results-Generating Duo of Lean Six Sigma

Six Sigma and Lean are not mutually exclusive approaches that must be deployed separately. In fact, for a more unified approach, Six Sigma and Lean may be used together under the banner of Lean Six Sigma. Six Sigma’s tools and methodologies enable businesses to pinpoint the cause and impact of process inputs and outputs. Lean eliminates waste from these processes and promotes operational excellence to provide maximum value to customers. Lean is focused on reducing the number of possibilities for failure, but Six Sigma is focused on lowering the probability of failure for each opportunity.

Higher-income, less waste, and improved processes are all advantages of Lean Six Sigma for businesses of all sizes and sectors.

The type of training you (or your organization) chooses will be influenced by the nature of your processes, the maturity of your company’s processes, and, most crucially, your personality and interests. Overall, businesses should strive to use all three techniques and will require personnel who are knowledgeable in each.

Posted in Lean, Lean Six Sigma, Six SigmaTagged Lean, Lean Six Sigma, Six SigmaLeave a Comment on Are Lean vs. Six Sigma vs. Lean Six Sigma Different, Similar, or Compatible?

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