Ensure Your Lean Six Sigma Project is Successful by Scoping It Properly

Posted by on May 27, 2019 in Lean Six Sigma, Project Scoping | 0 comments

Many Lean Six Sigma projects fail and flounder due to not scoping the project properly.  Sometimes teams try to take on too much and the project drags on forever.  Other times, scope creep enters and additional opportunities are explored causing delay and frustration.  The ultimate goal is for Lean Six Sigma teams to be successful and that means getting the project scope right!  Here is a list of the most common reasons why projects are not scoped correctly. Project boundaries not well defined Allowing scope creep to enter Unclear problem...

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Use Defined Criteria to Select Your Lean Six Sigma Projects

Posted by on May 19, 2019 in Customer Satisfaction, Lean Six Sigma, Project Selection Criteria | 0 comments

Organizations seem to struggle when it comes to identifying Lean Six Sigma or continuous improvement projects.  Sometimes they may be so overwhelmed with issues that it’s hard to know where to start.  When faced with this dilemma, the last thing you want to do is to select the project that is most obvious or let your Lean Six Sigma teams determine their own projects.  Instead, you want to bring discipline to the way you select projects. Projects selection is the responsibility of top management and must be linked directly to the...

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Want A Successful Lean Six Sigma Deployment? Follow These 12 Steps!

Posted by on May 9, 2019 in Continuous Improvement, Lean Six Sigma, Uncategorized | 0 comments

Having been involved in Lean Six Sigma for over 20 years, I’ve seen many organizations struggle with deploying Lean Six Sigma.  Some start off with great intentions but then seem to falter as they move forward. I am proud of the fact that I was part of a very successful Lean Six Sigma deployment at Delphi (now Aptiv).  Not that we did everything right, but we were were able to implement and sustain a very successful program.  Here is a list of the factors that I think made us successful: Designate a Deployment Champion.  This is...

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Not So Obvious Wastes That Kill Productivity

Posted by on May 4, 2019 in Energy Utilization, human resource utilization, safety | 0 comments

  There are many wastes beyond the more common ones of transportation, inventory, motion, waiting, overproduction, over-processing, and defects that hurt your productivity and efficiency.  In this post, I’ll address some of the ones that I’ve seen in many organizations. Safety In this day and age it’s hard to believe that employee safety is still a concern.  When you think about it an organization that allows its employees, or worse, forces employees to work in unsafe conditions is not a place you should even consider...

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Defects Create More Waste Than Meets The Eye!

Posted by on Apr 29, 2019 in Continuous Improvement, Customer Satisfaction, Lean Six Sigma, Problem Solving, Product Quality | 0 comments

Defects, mistakes, and errors are a major source of frustration for customers and cause them to look for other providers for the products and services they purchase.  But in addition to customer dissatisfaction, these defects, mistakes, and errors create waste that suck up our precious resources of time and money.  Employees are forced to rework and repair products and provide services all over again.  It’s been estimated (and a good rule of thumb) that the true cost of defects, errors, and mistakes is at least a factor of ten when...

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Over-Processing Adds Costs to Products and Services For Which You’re Not Getting Paid

Posted by on Apr 21, 2019 in Continuous Improvement, Efficiency, Lean, Overprocessing, Process Improvement | 0 comments

Ever stop to think how much you’re spending by over-processing the products and services you provide?  If not, its probably because you don’t fully understand what over-processing is all about. Over-processing is defined as all the extra effort people go through in order to deliver the product or service.  It’s actually giving something away for no return.  Let me give you some examples: Not having a well defined process where it takes more time to complete a task, product or service than it should All the extra...

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Producing Too Much Creates Waste!

Posted by on Apr 14, 2019 in Inventory Waste, Lean, overproduction | 0 comments

More! Sooner! Faster! When these expectations begin to drive processes, companies are likely to slip into overproduction.  As a result, they end up with more product than needed. Accumulating inventory before it is needed is an unwise use of resources.  It ties up cash that could be used more effectively.  It also causes other wastes such as extra transportation and motion.  Additional equipment and manpower are required to track the added inventory, along with the necessary storage areas, warehouses, and storage containers.  Utility and...

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Don’t Get Hung-Up In The Waiting Game

Posted by on Apr 7, 2019 in Continuous Improvement, Lean, Process Improvement | 0 comments

Waiting is a big part of our normal daily lives and something we typically take for granted.  We wait for our first cup of coffee in the morning; we wait at traffic lights on our way to work; we wait for people to show up for a meeting to start; we wait in doctor’s offices; we wait for the end of the day so we can leave work; we wait in checkout lines at the grocery store; and some of us even wait to use the bathroom! Waiting is one of the seven deadly wastes defined by Taichi Ohno, the father of the Toyota Production System....

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Is Too Much Motion Tiring You Out?

Posted by on Mar 31, 2019 in Kaizen, Lean, Process Improvement | 0 comments

  Masaaki Imai in his book, Gemba Kaizen, A Commonsense, Low-Cost Approach to Management, states that any motion of a person’s body not directly related to adding value is unproductive.  Some examples of motion waste include: Searching for jigs, fixtures, tools, files, etc. Bending to lift heavy loads Turning to retrieve or dispose of products Reaching for components and tools Placement of products in the production process Walking to printers, fax machines, store rooms, etc. In addition to causing productivity problems, excess...

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Too Much Inventory Will Destroy Your Operation!

Posted by on Mar 24, 2019 in Continuous Improvement, Inventory Waste, Lean | 0 comments

Inventory is a waste that plagues every organization and usually hides a multitude of sins.  In fact, inventory has been called the root of all evil.  Excessive inventory occurs when material is pushed through a process rather than being pulled by customer demand. Excessive inventory occurs in all organizations in the form of raw material, supplies, spare parts, work-in-process (WIP), finished goods, and office supplies.  Warehouses and valuable space are needed to handle the extra inventory requiring additional investment, resources, and...

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