How do you measure and reduce variation in plant operations using six sigma?

1 Define the problem

The first step in any six sigma project is to define the problem you want to solve. You need to identify the customer requirements, the current performance, the gap between them, and the impact of the problem on the business. You also need to define the scope, objectives, and resources of the project. You can use tools like the voice of the customer, the SIPOC diagram, and the project charter to help you define the problem clearly and concisely.

2 Measure the variation

The next step is to measure the variation in your process. You need to collect data on the key input and output variables that affect the quality of your product or service. You also need to verify the accuracy and reliability of your data and your measurement system. You can use tools like the data collection plan, the operational definition, the measurement system analysis, and the process capability analysis to help you measure the variation in your process.

3 Analyze the causes

The third step is to analyze the causes of the variation in your process. You need to identify the root causes of the problem and the factors that influence them. You also need to test your hypotheses and validate your assumptions using statistical methods. You can use tools like the fishbone diagram, the Pareto chart, the scatter plot, and the hypothesis testing to help you analyze the causes of the variation in your process.

4 Improve the process

The fourth step is to improve the process by eliminating or reducing the variation. You need to generate, evaluate, and select solutions that address the root causes of the problem and meet the customer requirements. You also need to implement the solutions and monitor their effects using pilot tests and control charts. You can use tools like the brainstorming, the matrix diagram, the design of experiments, and the FMEA to help you improve the process.

5 Control the process

The fifth step is to control the process by sustaining the improvement and preventing the variation from recurring. You need to standardize the new process and document the changes. You also need to train the staff and communicate the results. You can use tools like the control plan, the SOP, the mistake proofing, and the dashboard to help you control the process.

6 Review and improve

The sixth step is to review and improve the process by evaluating the performance and the benefits of the project. You need to compare the actual results with the expected results and calculate the savings and the return on investment. You also need to identify the lessons learned and the opportunities for further improvement. You can use tools like the before-and-after analysis, the benefit-cost analysis, the project report, and the feedback survey to help you review and improve the process.

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?