What are your best practices for Lean Six Sigma?

The back of a napkin can be the right tool in some instances. How do you know what's right? Intuition experience educated guessing Sometimes, you'll slip down the wrong rabbit hole. When that happens, recognize it quickly and try something new.

Lean Six Sigma Methodologies are versatile and can be applied to a wide range of situations. The effectiveness of these methodologies lies in the right selection of relevant tools which depend on the nature of the problem, the organizational context & the experience of the team members. DMAIC framework provides us a set of tools in each phase of problem solving. Most commonly used (powerful tools) for each stage are (not limited to): 1. Define-5 W 2H, Project Charter, RACI Model, SIPOC 2. Measure-VSM, Spaghetti Diagram, & various elements of MSA 3. Analyze- Root Cause Analysis, 5 Whys, Cause-and-Effect Diagram, Pareto Charts 4. Improve-5S, Kanban, Standard Work, Poka-yoke, Kaizen 5. Control-Control Plan, Control Charts, Visual Control, TPM

The Lean Six Sigma (LSS) methodology equips individuals with a versatile toolbox for problem-solving, much like a set of essential tools and complimented by experience during their day in and out on continuous improvement discussion. By integrating principles of lean management and Six Sigma, LSS offers a comprehensive approach to improving efficiency, reducing waste, and enhancing quality across various sectors. It does not only provide a structured framework for addressing complex issues but also fosters a culture of continuous improvement and operational excellence.

1. Define the Problem: Understand what needs fixing. 2. Know the Process: Understand how things work. 3. Pick Wisely: Choose tools that fit the problem. 4. Use Available Data: Work with what you have. 5. Involve Others: Get input from the team. 6. Keep it Simple: Don't overcomplicate things. 7. Adapt as Needed: Be flexible and adjust. 8. Train Your Team: Ensure everyone knows how to use the tools. Following these steps will help you select the right tools for Lean Six Sigma projects efficiently.

Lean Six Sigma best practices: 1. Define Project: Use DMAIC framework. 2. Measure Performance: Use data for improvement. 3. Involve Team: Ensure understanding of roles. 4. Continuous Improvement: Regularly review processes. 5. Training: Equip team with necessary skills. 6. Customer Focus: Aim for customer satisfaction. 7. Use Tools: Apply Lean Six Sigma tools.

John C Maxwell says,"One is too small a number to achieve greatness". The same applies to Lean Six Sigma Project also. Behind any Lean Six Sigma Project, there are many stakeholders who are involved directly or indirectly. The stakeholders are either affected by or have an interest in the project-customers, employees, suppliers, regulators. Involving the stakeholders from the early phase of the project is very important as the buy-in of the stakeholders is not only important for the success of the project, but also it increases the overall satisfaction and loyalty. To effectively involve the stakeholders, it is crucial to establish an open channel of communication, listen to them with empathy, take feedback & engage with them continuously.

In my experience, an often overlooked but crucial group of stakeholders are those directly involved in production steps. By actively involving them and utilizing Lean tools, such as Gemba walks or Kaizen events, we can tap into their frontline expertise to uncover root causes of problems. It's essential to keep all communication lines open and emphasize that every idea and suggestion is valuable. Empowering production teams to contribute to problem-solving fosters a culture of engagement and continuous improvement.

1. Identify: Find who's involved. 2. Communicate: Keep them informed. 3. Engage: Get them on board early. 4. Listen: Address concerns. 5. Show Value: Highlight benefits. 6. Celebrate: Acknowledge achievements. 7. Feedback: Keep improving together.

Lean Six Sigma best practices: 1. Understand Lean and Six Sigma principles. 2. Train and certify key team members. 3. Secure leadership commitment. 4. Select strategic, measurable projects. 5. Utilize Lean Six Sigma tools. 6. Make data-driven decisions. 7. Continually improve processes. 8. Foster a culture of continuous improvement.

During the Six Sigma project we need to involve the Cross functional team i.e. going across the team and it's well mentioned in the project charter so we need to delegate things across the team so and mapped the RACI Matrix and because without cross Functional team it's not going right direction so need involved the same

Lean Six Sigma consists of a set of Methodologies based on Lean Principles & Statistics to drive organizational Process improvements & problem solving. It uses DMAIC Framework to solve problems wherein the Phase 'IMPROVE' pertains to finding out solutions for the given problem. Validation is about testing the solution whether it can resolve issue, if it can then to what extent & finding out what it takes to implement the solution. Verification is a post-implementation activity which looks to check & confirm the effectiveness of the solution post implementation. Once the solution is validated and verified, one of the important points that shall be adhered to is to horizontally deploy the solution for similar problems across the organization.

Based on my experience, the different steps of the DMAIC methodology allow, through the improve phase, to identify possible solutions using brainstorming, benchmarking etc. Once solutions have been identified and evaluated in termes of feasibility and impacts (does it allow the company to answer its customers needs?), then the solutions chosen are tested through a pilot or a business case to ensure their feasibility and efficiency. It is only when feasibility and efficiency have been proved that new standards are set up and the solutions possibly duplicated.

Whenever we go to problems statements and the same things we find the correct action and RCA analysis and when we implement the action plan we need to validate the things through Gemba walk and go to see the things or GSTD so verification of action plan needs to be done properly this is the right way

In my experience, the phase CONTROL in DMAIC framework contains the elements of monitoring & sustaining the improvements achieved by any Lean Six Signa Project. This step is so very important, because this can make or break the overall outcome of any LSS Project. Classically, control can be effected through Control Plan, Control charts, Visual Controls etc. Organizations must develop robust monitoring system through Process monitoring, Audits, Surveys, Scorecards, Dashboards and also through regular structured reviews & feedback. Sustaining the improvements can be achieved by implementing Lessons Learnt, embedding the Learning to the Organizational Memory by appropriate Knowledge Management, Documentation & ongoing training and evaluation.

For sustainability we need to develop the SOP and One point lesson which displays in the area where we developed the things once results achieved we need to sustain by doing training and review and review the action plan also because we need to develop the same for future and horizontal deployment is also there so sustain the development is must by regular review

Continuously learning & improving is at the heart of any improvement methodology, particularly so in case of LSS. Methodologies like this stems from a few sets of principles & believing that continuous learning & improving is not only possible but also necessary is one of them. Adopting this requires a flexible & curious mindset that we can always improve & embedding this trait in the very DNA of the organization is one of the main jobs of LSS Practitioner. As industries change for new frontiers of Technology & Processes, to a Leaner, Efficient & Sustainable Organizations which embrace Change, Sustainability & Profitability taking care of People, Planet & Profit; it is imperative that we adopt CONTINUOUS IMPROVEMENT as a way of life.