Lean Sigma

is a methodology to improve the capability of business processes by reducing variability and elimination of defects in any process from transactional to product to service.

Six Sigma (6 s : 99.99966% accuracy – 3.4 defects per million) is a systematic methodology to improve the capability of business processes by reducing variability and eliminating defects in any process from transactional to product driven. It is a vehicle for strategic change…an organizational approach to performance excellence. Six Sigma creates transformational change throughout the organization, processes, culture and customers. It creates transactional change by applying tools and methodologies targeted at reducing variation and drastically improving processes. The process begins by defining the problem, those things Critical To Quality (CTQ). Then, you measure the performance of those CTQs. Next, you analyze the situation to find root causes of the problem and determine which problems have the most impact. With the causes identified, you're ready to improve the situation by initiating change. Finally, you need to ensure that the change lasts. The final step initiates measures to sustain the improvements you've made for long-term control. The goal then is to get to the root out the problem and ensure the solution is sustainable.

Our methodology engages all functional areas of an organization through the use of data, data, and more data. The Six Sigma process also identifies the critical components to improvement. The thoroughness of analysis allows improvement teams to find the most critical cause of “Y” or the unacceptable performance. This means they know what to fix “the critical X's “first which gets results quicker. It was pioneered by Motorola in 1980s where they discovered that products with high first-pass yield (the amount of product that made it through defect-free) seldom failed in use. Some key players in Six Sigma history were Mikel Harry - one of the original Motorola architects who later founded Six Sigma Academy; Jack Welch, CEO General Electric; and Larry Bossidy, CEO Allied Signal. This power philosophy promotes excellence in all business processes to improve productivity, profits, and customer satisfaction. The Methodology espouses a 5-phase process for continuous improving quality by reducing inherent variability.

Define	Measure	Analyze	Improve	Control
Identify the problem	Validate the problem / process	Develop causal hypotheses	Develop ideas to remove root causes	Establish standard measures to maintain performance
Define requirements	Refine problem/goal	Identify "vital few" root causes	Test solutions	Correct problem as needed
Set goal	Measure key steps/inputs	Validate hypothesis	Standardize solution and measure results

Process Design/Redesign Model

Define	Measure	Analyze	Improve	Control
Identify specific or broad problems	Measure performance to requirements	Identify "best practices"	Design new process	Establish measures & reviews to maintain performance
Define goal/change vision	Gather process efficiency data	Assess process design	Implement new process, structures, systems	Correct problems as needed
Clarify scope & customer requirements		Refine requirements

6 Lean Sigma Tools

Statistical Process Control
Design Of Experiments
Process Analysis
Financial Analysis
Organizational Development
Project Management
FMEA

Identify Core Processes & Key Customers	Define Customer Requirements	Measure Current Performance	Prioritize, Analyze & Implement Improvements	Expand & Integrate 6 Sigma System
Identify "Core" business processes	Gather customer data, Develop "Voice of Customer" strategy	Plan & execute performance against customer requirements	Select improvement projects & develop rational	Implement ongoing measures & actions to sustain improvement
Define process Outputs & key Customers	Develop performance standards & requirements statements	Develop baseline defect measures & identify improvement opportunities	Analyze, develop & implement root cause-focused solutions	Define responsibility for ownership & management
Create high-level Core process maps	Analyze & prioritize requirements; evaluate per business strategy		Design/redesign and implement effective new process	Execute "closed-loop" management & drive to 6 Sigma

Key Benefits

20% improvement in margin
2% - 18% increase in capacity
10% - 30% reduction capital spend