How do you apply lean or six sigma principles in your plant?

1 Understand the problem

Before you implement any lean or six sigma project, you need to understand the problem you are trying to solve. What is the current state of your process, product, or service? What are the customer requirements and expectations? What are the sources of waste, defects, or inefficiencies? You can use tools such as value stream mapping, fishbone diagrams, or Pareto charts to analyze the problem and identify the root causes.

2 Define the goal

Once you have a clear picture of the problem, you need to define the goal of your improvement project. What are the desired outcomes and benefits? How will you measure them? What are the key performance indicators (KPIs) and targets? You can use tools such as SMART goals, project charters, or SIPOC diagrams to define the scope, objectives, and deliverables of your project.

3 Choose the approach

Depending on the nature and complexity of your problem and goal, you can choose the appropriate approach for your project. Lean focuses on eliminating waste and optimizing the flow of value to the customer. Six sigma focuses on reducing variation and improving the quality of the output. You can use tools such as 5S, kanban, or kaizen for lean projects, or DMAIC, DMADV, or DFSS for six sigma projects. You can also combine lean and six sigma principles to achieve both efficiency and effectiveness.

4 Implement the solution

After you have chosen the approach, you need to implement the solution in your plant. This involves testing, validating, and refining your ideas, as well as engaging and training your team members and stakeholders. You can use tools such as pilot runs, control charts, or poka-yoke to ensure that your solution works as intended and meets the customer requirements.

5 Monitor the results

The final step is to monitor the results of your project and evaluate its impact on your plant operations. You need to collect and analyze data to verify that your solution has achieved the goal and improved the KPIs. You also need to check for any unintended consequences or new problems that may arise. You can use tools such as dashboards, audits, or feedback surveys to monitor the results and make adjustments if needed.

6 Sustain the improvement

The last but not least tip is to sustain the improvement and prevent backsliding. You need to standardize and document your new processes, products, or services, as well as communicate and celebrate your achievements. You also need to foster a culture of continuous improvement and encourage your team members and stakeholders to identify and solve new problems. You can use tools such as gemba walks, huddles, or PDCA cycles to sustain the improvement and keep learning.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?