Lean sigma project teams lead the way in continuous improvement.
The focus of lean manufacturing is efficiency --- reducing waste and increasing speed. Six sigma focuses on quality --- eliminating defects by reducing process variability. Lean sigma combines both disciplines to achieve the joint goals of speed and quality. Continuous improvement projects led by cross-functional teams are major drivers of organizational change.
Lean Sigma Project Philosophy
Lean six sigma, or lean sigma as it is more commonly called, follows a structured approach to problem solving and continuous improvement projects. The goal of lean sigma culture in an organization is not to overhaul every aspect of the company all at once.
Instead, through small, manageable projects, daily processes are streamlined and rendered free of defects over time. The sharing of best practices through an organization is what allows even a small project completed by a single person to positively impact an entire corporation.
Types of Lean Sigma Projects
Kaizen is a term which includes all lean sigma projects. It is a combination of the Japanese words kai and and zen and simply means "continuous improvement." Some kaizen projects are the work of only moments while others take considerable time and energy. Not all projects require the full lean sigma tool set.
Quick wins are continuous improvement projects that can be implemented quickly and begin delivering results as soon as they are complete. A quick win could be as simple as moving a tool cabinet a few feet to clear a walking path.
Mistake-proofing projects implement measures designed to make it impossible to make a mistake at a given process step. An example of mistake proofing would be creating a jig so that a part can only be installed in the proper direction.
So-called 5S projects are focused on improving safety and efficiency through organization, maintenance, and cleanliness of a work area; 5S stands for sort, set in order, standardize, systematic cleaning and sustain.
DMAIC problem-solving projects are the most involved lean sigma projects. These projects may require cross functional teams with several members and will require the use of more advanced lean sigma tools.
DMAIC Methodology
DMAIC is an acronym that stands for define, measure, analyze, improve and control. The five phases of DMAIC offer a structured approach to problem solving within the lean sigma system.
During the define phase, the project charter is created, spelling out the problem which needs to be solved, the scope of the project, the business case for spending resources on solving the problem and the expected return on investment. The measure phase involves "walking the process," or going to the actual place where the work is done and seeing the process first hand . Team members walk through and map out the various steps of the process and gather data on the current state of the process.
During the analyze phase, root cause analysis leads the team to the heart of the problem that needs to be solved. Defect opportunities observed during the measure phase will be prioritized by calculating their potential impact using tools like Pareto charts and failure mode effect analysis, or FMEA.
The improve phase of the project is where potential solutions to the defect opportunities prioritized in the previous phase are proposed, tested and refined. The major deliverable of the improve phase is the improvement plan, a document which spells out the specific steps and resources needed to improve and control the process.
Finally, the control phase begins after the improvement plan has been implemented. The control phase goes on indefinitely because its goal is to keep the process from deteriorating back into its prior state.
Assembling a Lean Sigma Project Team
The size of your team will depend on the scope of the project. A quick win may only require one or two people to complete. However a full scale DMAIC project may require several.
Your project team will need to include a project leader, usually a lean sigma green belt or black belt, a recorder to keep notes and representatives from each functional area that is a stakeholder of the process. A stakeholder is anyone who will be affected by the outcome of the project.
Stakeholder management is a critical and often overlooked factor when lean sigma projects are put together. While a team can come up with great ideas during the improve phase, a project will ultimately fail to deliver on its promise if it is not accepted into the organizational culture. Seeking the input of all interested parties will help avoid resistance when the improvement plan is put in place.
Tags: continuous improvement, improve phase, improvement plan, improvement projects, lean sigma, lean sigma projects, phase project
