Process Improvement with Lean Six Sigma
Have you ever worked with a process that felt outdated?
Or perhaps your team has done things a certain way because “it’s always been this way”. If you’ve encountered a roadblock at work and thought to yourself “there must be a better way!” then you already have the right mindset to get started with Lean Six Sigma (LSS)!
Lean Six Sigma is a process improvement approach that can help us reduce blocks in our workflow by working through five phases: define, measure, analyze, improve, and control (DMAIC).
Define the problem or opportunity and the performance outcome that you want to improve.
Activities
- Write a problem statement that defines the problem
- Define the process improvement scope and objectives
- Identify stakeholders and team members
- Communicate project objectives
Benefits
- Aligns team goals and objectives by establishing a shared understanding of the issue
- Sets the scope and boundaries of the project
Tools to Consider: Project charter; Gantt Chart; Stakeholder Analysis; A3; Suppliers, inputs, process, outputs, customers (SIPOC); Voice of the Customer (VOC)
Collect relevant data to depict the current state. This creates a baseline to compare future performance.
Activities
- Choose key metrics and performance indicators that align with the objectives from the define phase
- Collect data on the current process by mapping the current state of the process, identify pain points, what is critical to the customer.
Benefits
- Identifies key performance metrics
- Creates a foundation for analyzing and improving the process before improvements are made
Tools to Consider: Value Stream Map; Tick Chart; Spaghetti Diagram; Data Collection Plan
Identify the root causes of the problem. By understanding why the problem occurs, you can develop targeted solutions.
Activities
- Analyze the data collected
- Identify patterns waste or non-value added activities
- Determine the root cause of the process pain points
Benefits
- Develop solutions that target the root causes, rather than addressing surface-level symptoms.
- Ensures that the improvements are effective and sustainable
Tools to Consider: Fishbone Diagram; 5 Whys
Design and implement solutions that address the root causes.
Activities
- Brainstorm potential solutions to address the key root causes of pain points
- Evaluate alternatives
- Select solutions to pilot and implement
- Implement process changes
- Continuously monitor the improvements; adjust as needed
Benefits
- Implement effective, data-informed solutions
- Drive measurable improvements in the process
Tools to Consider: Failure Mode and Effects Analysis (FEMA); Impact/Effort Matrix; Future State Map
Sustain your achievements! Monitor and maintain progress.
Activities
- Develop a plan to monitor, evaluate and control the process
- Update standard operating procedure documents to incorporate your new process controls
- Develop any necessary training plans
- Monitor key performance indicators
- Determine improved process capability and validate results of process improvement
- Document lessons learned and best practices
Benefits
- Ensure that improvements are maintained and reviewed over time
- Prevents regression to previous performance levels
- Establishes on-going feedback and team alignment
- Celebrate your wins!
Tools to Consider: Control Plan; Process Documentation; Training and Knowledge Transfer Plan
Learn More
Resources
DMAIC Tools for Continuous Improvement
Our resources will guide you every step of the way. Start exploring our library of resources below.
Learning & Development
Earn a Lean Six Sigma Certificate
Beginning Fall 2024, UTM staff can earn a Lean Six Sigma White or Yellow Belt through the PMO, free-of-cost.
Community
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