Lean Six Sigma Tools and Techniques You Need to Know
Lean Six Sigma Tools and Techniques You Need to Know
Some
businesses aspire for transformation, others make it happen. Many of those who
succeed at driving change — including most Fortune 100 companies, do so by
applying the principles and processes of Lean Six Sigma. Developed to sustain
customer satisfaction and deliver high-quality output, Lean Six Sigma is a
process improvement method that harnesses teamwork to systematically boost
operational efficiencies and reduce waste. Lean Six Sigma evolved from the fusion
of two related disciplines, lean manufacturing and Six Sigma, that have
successfully achieved dramatic improvements in the profitability of
organizations across different industries. So let's go over Lean Six Sigma
tools and techniques you need to know. As a data-driven method, Lean Six Sigma
uses precise tools and techniques to identify challenges, solve problems, and
attain business goals. For the most part, these tools and techniques relate to
specific stages in the improvement cycle denoted as DMAIC (Define, Measure,
Analyze, Improve, Control). Many of the techniques and tools used by Lean Six
Sigma practitioners have been around well before the process improvement method
was formalized. Many were used in business analysis, relationship
visualizations, project management, and other fields. The affectivity of
specific tools and techniques depends heavily on their fitness when it comes to
an organization’s unique situation, business model, and corporate culture.
Define
·
Failure
Mode & Effects Analysis (FMEA): A model that
helps professionals analyze and prioritize weaknesses and potential defects of
a design or process based on factors such as severity and frequency of
occurrence.
·
Process
Flow Charts:
A commonly used visual aid that shows the steps or stages of a process. This
top-level diagram lends clarity to an improvement project and brings everyone
on the same page.
·
Project
Charter:
A document primarily used in project management that sets the parameters of a
process improvement project. While a project charter plays a
major role in the Define phase of DMAIC, it also serves as a tool in the
Control stage.
·
RACI Matrix: Acronym for Responsible, Accountable, Consulted,
and Informed. This matrix outlines all the roles and responsibilities related
to every activity/task in a process or project.
·
TAKT Time: The rate
(expressed in time units) at which a business needs to complete a product to
meet customer demand.
·
Value Stream Map: A very detailed type of process flow
chart that visualizes all the steps in a process that are required to deliver
value from start to finish. It is originally a lean management tool for mapping
all the activities needed to create a product and get it into the hands of the
end-customer.
Measure
·
Histogram: A bar chart that shows frequency distribution
or variation in a data set. It is often used to a) identify which factors
contribute most to the occurrence of a problem, and b) determine the capability
of a process to consistently generate an acceptable output.
·
Pareto Chart: A histogram that shows the relative
significance/impact of defects or variances in a system. It helps determine
where the bulk of defects occur, effectively clarifying the cause and effect of
problems and identifying the specific area that needs improvement the most.
Analyze
·
5 Whys Analysis: A straightforward method for
determining the root cause of a problem. The method prescribes asking “why” a
problem occurs five times in succession to sift through mere symptoms and
eventually zero in on the real factor that causes the problem.
·
Design of
Experiments:
A systematic technique for testing the relationships between different factors
with the purpose of creating the best-case design (i.e., optimal performance of
features and functions) for a process or system.
·
Fishbone
Diagram:
A visualization technique for mapping all possible causes of a problem based on
logical categories, with the aim of identifying root causes. Also called
cause-and-effect or Ishikawa diagram, fishbone diagrams are often used during
brainstorming sessions.
·
Regression
Analysis:
A statistical tool for understanding the relationship between output and input
variables, and making predictions based on the relationship.
Improve
·
5S: A five-step method for keeping workplaces orderly and for motivating
workers to maintain discipline and optimal process/workflow conditions. The
term originally referred to five Japanese words whose English equivalents are
Sort, Straighten, Shine, Standardize, and Sustain.
·
A3 Process/Report: A systematic approach to solving
problems and driving continuous improvement that is typically
documented/simplified/visualized on a sheet of A3-size paper, hence the name.
·
Kanban: A graphical scheduling system named after the Japanese terms for “visual”
(kan) and “card” or “board” (ban). The system is designed to optimize the
production process by reducing idle time and inventory.
·
Kaizen: A mindset of continuous improvement. It holds
that everything can undergo incremental improvements over time. Kaizen
advocates for proactive teamwork and the elimination of waste.
·
Poka Yoke (Error-Proofing): A mistake prevention approach that aims to
eliminate product defects by preventing, correcting, and signaling the
occurrence of human errors as they happen. Named after the Japanese terms for
“error” and “machine operator,” poka-yoke refers to any mechanism in a process
that reduces the frequency of mistakes, with the ultimate goal of enabling
people and processes to get things right the first time.
·
Single-Minute Exchange of Die (SMED): A method
associated with lean manufacturing that reduces the time it takes to run the
current product to run the next. It is used to accelerate cycle time, reduce
costs, and enhance the adaptability of processes. Also called Quick Changeover.
·
Total Productive Maintenance (TPM): A methodology
for maintaining and improving the quality of systems, processes, and machines.
TPM specifically aims to reduce loses that are incurred when unplanned downtime
occurs.
Control
·
Control
Charts:
A time-based visualization that is used to monitor and improve quality. Control
charts are major tools used in statistical process control. Also called the
process behavior chart.
·
Standardized
Work:
A baseline concept in kaizen or continuous improvement that is used as a tool
for keeping productivity and quality at optimum levels. Standardized work
documents the current best practice. When a new and improved system is adopted,
it becomes the new standardized work.
·
Statistical
Process Control (SPC): A methodology
that uses statistical tools to monitor, control, and improve the quality of
processes.
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