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Lean and Six Sigma Approach

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. ​
Lean Six Sigma Approach Diagram
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. It is a vehicle for strategic change and 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 process performance. 

The process begins by defining the problem, those things Critical To Quality (CTQ). Then measure the performance of those CTQs. Next, analyze the gaps between actual and planned output 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 repeatable and 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. Focusing on the “x’s” will allow identification of those “critical few” which are causing the undesired outcome.  Teams will know what to address “first” to achieve quicker results.  

6 Lean and Sigma  Tools

Statistical Process Control
Design of Experiments
Process Analysis
Organizational Development
Project Management
FMEA

Key Benefits

 20% Improvement in Margin
 2%-18% Increase in Capacity
 10%-30% Reduction of Capital Spend

Phased Model

Define

Identify the Problem
Define Requirements
Set Goal

Measure

Validate the Problem/Process
Refine Problem/Goal
Measure Key Steps/Inputs

Analyze

Develop Causal Hypotheses
Identify "Vital Few" Root Causes
Validate Hypothesis

Improve

Develop Ideas to Remove Root Causes
Test Solutions
Standardize Solution and Measure Results

Control

Establish Standard Metrics Maintain Performance
Correct Problem as Needed
Six Sigma was pioneered by Motorola in 1980's where they discovered that products with high first-pass yield (the amount of product that made it through defect-free) seldom failed in use.  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. 

Process Redesign Model

Define

Identify Specific or Broad Problems
Define Goal/Change Vision
Clarify Scope & Customer Requriements

Measure

Measure Performance to Requirements
Gather Process Efficiency Data

Analyze

Identify "Best Practices"
Process Capability
Refine Improvement

Improve

Design New Process
Implement New Process, Structure, System

Control

Establish Measures & Reviews to Maintain Performance
Correct Problems as Needed
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