Archive for Lean six sigma
You can implement Poka-Yoke
Posted by: | CommentsThese are the the tools I use for Poka-Yoke Implementation. It will make you as “Smart as a 5th Grader.” Yes, this is not rocket scientist stuff. It is easy and simple. Now, these methods alone will not get you to Six Sigma Quality levels but they will start you on the path of continuous and measured improvement. So what are the tools?
The first tool I use may not be considered a tool at all, it is a mind set, This is NOT WHAT to DO. I keep this diagram around and embed it in most of things that are printed. It is very simple but the key to making a successful Poka-Yoke campaign.
The Fishbone Diagram is a graphical compilation used to identify and explore the possible causes which lead to a given mistake. The ultimate aim is to work down through the causes to identify basic root causes of a problem. Related Blog Post.
Organize your mistakes(errors) and group them according to the Matrix. This will simplify the selection process on what mistake to tackle first.
I also have a list of Common Red Flag Conditions. These are quick places to look to assist you in finding the reason for the defect. You could maybe determine these to be your first “WHY” in your search for the root cause. The only thing I would warn you is not to jump to a conclusion. Insert a few these into your fishbone and go through the steps. Use at a brainstorming session to get those ideas flowing.
- Frequent changes to a job
- Complex processes
- Lack of Standards
- Lack of measurement systems
- Lack of training
- Long cycle times
- Infrequent jobs
- High output
- Environmental conditions
- Attitude ( Motivation)
The one tool that I left is the project sheet. We will start completing the components of this in the next blog and start creating a Poka-Yoke process in it’s entirety.
Lean Six Sigma Marketing and Duct Tape Marketing – Original Comparison
Posted by: | CommentsI published this article practically a year ago in a series of blog posts. I thought with the recent increase in Lean Six Sigma Online Training and how you reduce waste in marketing that it was an opportune time to re-publish.
If you going to improve something, improve it!
Posted by: | CommentsWhy waste everyone’s time?
Some may have been thinking that we have been wasting our time. But changing the process without the data is cause for failure. You have heard it time and time again, JUST DO IT! We have been trained that way, action is accomplishment. But the wrong action may accomplish little or drive you deeper into a hole. Without the data from the previous steps, you will not be able to make as effective and dramatic improvements that you desire. Seek 200% procees improvements and cost reductions of half!
If you have Defined, Measured and Analyzed, if nothing else you are one smart cookie. More importantly, if your team has survived, this is the stage they will come back together and the excitement can be re-kindled. Let’s put it all into action: In the Improved stage, we must find and implement solutions that will eliminate the cause of problems. We typically go through a five step process.
1. Generate ideas.
2. Refine ideas.
3. Select a solution
4. Test.
5. Implement
I have a tendency to use two different tools at this point: One being an impact/effort matrix and the other being a tree diagram. As we are generating ideas are refining ideas. If we can place the ideas in impact/effort matrix it simplifies the solution process. So, after we are done brainstorming using the famous posted notes method, just post the notes into their appropriate squares, as we see fit. You may even segment them in the squares themselves as your reviewing them. Ask yourself is this easier to do than this? Or will this have minimum impact from a customer standpoint. It is even great to have an online focus group of customers, operations, sales, etc., that are willing to participate and pick which solutions will have the greatest impact.
So let’s say we have narrowed our solutions but we have 2 or 3 really good ideas but have difficulty deciding on which one to test. A tree diagram is what I use. The reason I wait to this stage is that I did not want to limit any ideas at the beginning. Using the tree diagram allows me to expand on each idea and drill down on how difficult it will be to implement and the exact strategies and tactics and even resources that may be needed.
Testing follows a project planning guideline that is somewhat beyond the scope of this blog post, but what it is a mini-project in itself with one more important ingredient. Ask yourself two questions: Did we get the results we wanted and did we follow the procedures outline? Don’t fall in love with your idea that you compromise the results.
After the testing, we are actually ready to implement, except we have to put some controls in for stability of the process! Don’t settle for routine improvements. If you want your creative juices to flow, push yourself to eliminate and make radical improvement of 200% or more. Seek cost reductions of half or more. Go for it!
