How to Write Up a Lean Six Sigma Project

Created by Motorola in 1981, Six Sigma is a business management strategy to improve operations. Writing up what is called a Lean Six Sigma project requires extensive understanding of both Lean and Six Sigma concepts, as well as knowledge of how to integrate the two. Lean technology calls for shedding of all wastes from an organization's processes, while Six Sigma is the process of identifying and removing root causes of defects in those processes. A project combining the two can help an organization deliver the best quality products or services and also improve its bottom line.

Instructions

Instructions

1. Identify and define the waste and defects in the processes. This will help define the project's scope and applicability. Cover the project from all possible aspects. Lean management principles have identified eight wastages in an organization's processes, including wasted human talent; defects; inventory; overproduction; waiting time; motion; transportation; and processing waste. These wastages can also be defined as defects under Six Sigma.

2. Measure the extent to which these wastages or defects are rampant in the organization and the levels to which processes can be streamlined by removing these wastages. As both Lean and Six Sigma focus on effective use of resources and minimizing time taken from initiation to delivery, proper measurement of these wastages or defects will also allow clear identification of the wastage in terms of time taken in creation of final deliverables.

3. Analyze the effects of these wastages on the overall product quality and value. Based on the findings, design alternative methods of carrying out the processes that cut out the wastages and add value in terms of quality and reduction in process timing. The analysis should also clarify the cause-effect relationships between wastages, time, and quality of processes. All possible factors should be taken into consideration with special focus on the root causes of defects to be addressed.

4. Suggest changes to existing processes with the aim of improving and optimizing them, as well as removing any of the eight wastages defined in step 1. Set up benchmarks and standardize processes to create new processes that deliver better quality in less time. Apply statistical data analysis techniques to all data collected to get a fair idea about the scope of changes required. Once the changes have been finalized and approved, set up test runs to check the new processes for quality capabilities and stability.

5. Set up control checkpoints for all future processes that regularly check the new processes against pre-defined benchmarks. The checkpoints should be exhaustively designed to identify potential variations before they turn into defects. These control systems should also allow for continuous monitoring of the processes through data gathering and statistical analysis of this data for preempting potential variation points in the processes.

Tips & Warnings

• Writing a Lean Six Sigma project is not for beginners and requires extensive training and experience of both Lean and Six Sigma concepts. Ideally, a Lean Six Sigma project should be written-up by a Six Sigma Black Belt or Master Black Belt, who have in-depth understanding of Lean techniques.

References

• Integrating Lean and Six Sigma
• Lean Six Sigma
• Lean Six Sigma Tools and Techniques