How do you apply lean six sigma to complex consulting projects?

1 Define the problem and the scope

The first step of any lean six sigma project is to define the problem and the scope of the improvement. This means identifying the customer's needs and expectations, the current state of the process, the desired state of the process, and the gap between them. You also need to define the boundaries and constraints of the project, such as the budget, timeline, resources, and risks. A useful tool for this step is the SIPOC diagram, which stands for Suppliers, Inputs, Process, Outputs, and Customers. It helps you map out the key elements and stakeholders of the process and clarify their roles and responsibilities.

2 Measure the current performance

The next step is to measure the current performance of the process and collect relevant data. This will help you establish a baseline and quantify the problem and the opportunity for improvement. You need to select the appropriate metrics and indicators that reflect the customer's requirements and the process goals. Some common metrics are cycle time, defect rate, customer satisfaction, and cost. You also need to ensure the data is accurate, reliable, and representative of the process. A useful tool for this step is the data collection plan, which outlines the data sources, methods, frequency, and analysis techniques.

4 Improve the process

The fourth step is to improve the process by designing and implementing solutions that address the root causes and eliminate or reduce the waste and variation. This means generating and evaluating various ideas and alternatives that can improve the process performance and the customer value. You need to use creativity and innovation techniques to brainstorm and prioritize the solutions. Some common techniques are the affinity diagram, the brainstorming, the nominal group technique, and the multicriteria decision analysis. The goal of this step is to select and test the best solutions that can achieve the desired state of the process and the customer.

5 Control the process

The final step is to control the process by monitoring and sustaining the improvements and ensuring they are aligned with the customer's needs and expectations. This means establishing and implementing control mechanisms and standards that can prevent the process from reverting to the old state and detect any deviations or issues. You also need to document and communicate the results and the lessons learned from the project and celebrate the achievements and the benefits. A useful tool for this step is the control chart, which tracks the process performance over time and signals any variations or trends.