I often think there is a gap in what we learn and how we use that knowledge in real-life situations to analyze and solve problems, especially when it relates to statistical techniques and their use. Using Lean Six Sigma tools and methods should be the way we think and analyze situations we encounter in our every day lives. Let me give you a few examples to prove my point.
- Control charts can be used to measure error rates overtime to set accuracy performance baselines.
- Capability analysis can help determine process improvement targets for teams
- Measurement system analysis (MSA) can help ensure auditing processes are accurate and precise for subsequent data collection and analysis. I once led a Human Resource team to determine the repeatability and reproducibility of their candidate interview process using MSA.
- Pareto analysis can help break the collected data into categories by their frequency of occurrence. This will help focus the project’s problem statement on the major causes of error.
- Box plots, histograms, run charts, and other graphical tools can help improvement teams compare error rates between workers, shifts, machines, suppliers, and other demographic factors to continue their root cause analysis.
- Failure mode and effects analysis (FMEA) can help a team identify potential design and process failure modes and provides a method to prioritize and either eliminate or reduce them.
- Process flow charts provide a visual representation so that all team members have a common understanding of the process and can be used as the basis for continual improvement.
- Is – Is Not diagrams provide a method to analyze problems that occur in processes and compare where the problem occurs to where the problem doesn’t occur.
- Fishbone diagrams map all possible causes of a problem based on logical categories and help determine the root causes.
- 5 Why analysis provides a straightforward method for determining the root cause of a problem by simply asking “why” a number of times to dive down to the real cause of the problem.
- Design of experiments (DOE) is a systematic technique that allows a team to proactively interfere with a process to determine the factors affecting it.
- Regression analysis is a statistical technique used to understand the relationship between output and input variables and allows predictions to be made based on those relationships.
- 5S is a 5-step process for organizing and sustaining improvement in the workplace, making it more efficient and productive.
- Kaizen is an improvement process that focuses on small everyday improvements that improve efficiency and productivity.
- Standardized work documents the best practice for performing a task or work process, which drives consistency between workers.
These are just a few of the tools and methods used in Lean Six Sigma that can help change the way you think, analyze, and solve problems. All of them are straightforward, easy to learn, and apply. Using today’s software you can torture data in a matter of minutes. This can lead to better process understanding and faster improvements.