How can you tell if your Six Sigma project is on track?

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Six Sigma is a data-driven methodology for improving quality and reducing variation in any process. However, implementing a Six Sigma project is not a one-time event, but a continuous cycle of planning, executing, monitoring, and controlling. How can you tell if your Six Sigma project is on track and delivering the expected results? Here are some tips to help you measure and evaluate your project performance.

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Kamesh Sundaram

I love inventing, innovative design, intelligent manufacturing and efficient processing. I love to train people to…

1 Define the project scope and goals

Before you start any Six Sigma project, you need to have a clear and realistic definition of what you want to achieve, why it is important, and how you will measure success. This is where you use the DMAIC (Define, Measure, Analyze, Improve, Control) framework to outline the problem statement, the project scope, the customer requirements, the process map, the baseline data, and the project goals. You should also identify the key stakeholders, the team members, and their roles and responsibilities. Having a well-defined project scope and goals will help you set the direction, scope, and boundaries of your project and avoid scope creep.

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William Morales

Medical Device Engineering | Lean Six Sigma Black Belt | Process Validation | New Product Introduction | Process Improvement and Cost Reduction Projects
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Before defining the project scope, you need to identify the PROBLEM the project is trying to solve. ALL projects are efforts at solving a problem. You may not know what the problem is or was originally, but you better find out. Otherwise, your project will become a solution waiting for a problem and sooner or later will die out (often slowly). How do you go about identifying the problem? Simple: identify and talk to the stakeholders. Often, they will all have different ideas of what the problem is. Or there may be more than one problem. It is impossible to develop the scope without these insights from stakeholders. Only after a proper Problem Statement is developed, are we able to develop an initial Scope Statement.

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2 Track the project progress and milestones

Once you have defined the project scope and goals, you need to track the project progress and milestones regularly and communicate them to the stakeholders. This is where you use tools like Gantt charts, dashboards, status reports, and meetings to monitor the schedule, budget, resources, risks, and issues of your project. You should also use control charts, Pareto charts, histograms, and other statistical tools to track the process performance and variation. Tracking the project progress and milestones will help you identify any deviations, delays, or problems that may affect your project outcomes and take corrective actions as needed.

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William Morales

Medical Device Engineering | Lean Six Sigma Black Belt | Process Validation | New Product Introduction | Process Improvement and Cost Reduction Projects
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Set up a project dashboard consisting of key performance indicators (KPIs), milestones, and other helpful information to track progress. Traffic signal colors: green = on-track, yellow = at-risk, red = delayed, will serve to convey status information quickly and in a visually appealing way. Importantly, determine the project's critical path (CP) and review regularly, as the activities in the CP will determine the completion date. Finally, list project risks or obstacles together with mitigation or contingency actions. This will give them visibility and ensure they are addressed by the team.

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3 Review the project deliverables and outcomes

After you have completed the project activities and implemented the improvements, you need to review the project deliverables and outcomes and compare them with the project goals. This is where you use tools like run charts, capability analysis, hypothesis testing, and cost-benefit analysis to evaluate the impact of your project on the process quality, customer satisfaction, and business performance. You should also document the lessons learned, best practices, and recommendations for future projects. Reviewing the project deliverables and outcomes will help you validate the effectiveness of your project and quantify the benefits and savings.

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William Morales

Medical Device Engineering | Lean Six Sigma Black Belt | Process Validation | New Product Introduction | Process Improvement and Cost Reduction Projects
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This is where the "C" (check) in the PDCA cycle comes in. Check to make sure the results, as delivered, meet the expectations of the stakeholders and the pre-determined objective acceptance criteria. Ideally, this checking should be done over a sufficient period to ensure the results are consistently capable. Do this, however, as a project activity itself - NOT after the project is concluded. That way, if additional actions are needed to satisfy the requirements, the project team is in place to accomplish those tasks.

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4 Sustain the project results and improvements

Finally, you need to sustain the project results and improvements and ensure that they are embedded in the process and culture. This is where you use tools like control plans, standard operating procedures, audits, and training to maintain the process control and stability. You should also use feedback mechanisms, recognition systems, and continuous improvement cycles to encourage the process owners and operators to adhere to the new standards and seek further opportunities for improvement. Sustaining the project results and improvements will help you prevent regression and erosion of your project gains.

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William Morales

Medical Device Engineering | Lean Six Sigma Black Belt | Process Validation | New Product Introduction | Process Improvement and Cost Reduction Projects
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Sustaining the gains is the toughest part of all. The project team has moved on and others will likely run the manufacturing process on a day-to-day basis. Knowing this beforehand, it is important that we integrate from the very start of the project those who will be key in the Sustain phase of the initiative. This ensures there is buy-in to the project, its goals, and the importance of maintaining the gains!

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5 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?

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Kamesh Sundaram

I love inventing, innovative design, intelligent manufacturing and efficient processing. I love to train people to achieve these goals.
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Like mentioned in the age old wisdom statement, the proof of the pudding is in the eating. Effective implementation is measured by its impact and acceptance which can only be achieved by data based decisions, inclusive project development and a culture of partnership.

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William Morales

Medical Device Engineering | Lean Six Sigma Black Belt | Process Validation | New Product Introduction | Process Improvement and Cost Reduction Projects
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Having a Plan A, a Plan B, and a Plan C really helps! Often, there are multiple ways the project's goals can be achieved. This is why knowing the problem you're trying to solve is key: it will enable the project team to have an open mind in considering all the possible solutions.

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How can you tell if your Six Sigma project is on track?

1

2

3

4

5

1 Define the project scope and goals

2 Track the project progress and milestones

3 Review the project deliverables and outcomes

4 Sustain the project results and improvements

5 Here’s what else to consider

Lean Manufacturing

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How can you tell if your Six Sigma project is on track?

1

2

3

4

5

1 Define the project scope and goals

2 Track the project progress and milestones

3 Review the project deliverables and outcomes

4 Sustain the project results and improvements

5 Here’s what else to consider

Lean Manufacturing

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