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What are the best ways to ensure continuous improvement in Six Sigma process design?

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Six Sigma is a popular methodology for improving the quality and efficiency of business processes by reducing variation and defects. However, achieving Six Sigma excellence is not a one-time project, but a continuous journey that requires constant monitoring, evaluation, and improvement. In this article, you will learn some of the best ways to ensure continuous improvement in Six Sigma process design.

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John Burke
Hariyadi Nugroho

Quality Consultant | Senior Quality Engineer | AI & Localization | SEO
Flávia Aparecida Zanin Chagas

Engenheira Química | Gest?o de Projetos | Green Belt

1 Define your goals and metrics

The first step to continuous improvement is to define your goals and metrics for each process. You need to have a clear vision of what you want to achieve, how you will measure it, and what are the acceptable standards and targets. You can use tools such as SMART (Specific, Measurable, Achievable, Relevant, and Time-bound) criteria, balanced scorecards, and key performance indicators (KPIs) to set your goals and metrics.

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Hariyadi Nugroho

Quality Consultant | Senior Quality Engineer | AI & Localization | SEO
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In real world there is dilemma setting up target for (example OQC) when you chose certain item (example: pass yield) as KPI. Inspectors find defects will score bad. They will then “negotiate” the condition. So, how to avoid this? Is by setting the next process target as our target. Customer complaint would more appropriate to be set as OQC KPI. OQC Pass yield should be the target of the Production line KPI, etc.

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2 Implement the DMAIC cycle

The second step to continuous improvement is to implement the DMAIC cycle, which stands for Define, Measure, Analyze, Improve, and Control. This is the core framework of Six Sigma that guides you through the process of identifying problems, collecting data, finding root causes, implementing solutions, and sustaining results. You can use various tools and techniques within each phase of the DMAIC cycle, such as process mapping, fishbone diagrams, Pareto charts, hypothesis testing, design of experiments, control charts, and standard operating procedures.

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3 Involve and empower your team

The third step to continuous improvement is to involve and empower your team in the Six Sigma process design. You need to have a cross-functional team that represents different perspectives, roles, and skills in the process. You also need to provide them with adequate training, coaching, and feedback on Six Sigma principles, tools, and techniques. You should encourage them to participate in problem-solving, decision-making, and improvement activities, and recognize and reward their contributions and achievements.

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Flávia Aparecida Zanin Chagas

Engenheira Química | Gest?o de Projetos | Green Belt
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As important as involving the team in the Six Sigma implementation phase is having clear communication about the results obtained. Using concrete data to maintain engagement.

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4 Adopt a customer-centric mindset

The fourth step to continuous improvement is to adopt a customer-centric mindset in the Six Sigma process design. You need to understand who your customers are, what their needs and expectations are, and how you can deliver value to them. You can use tools such as voice of the customer (VOC), customer satisfaction surveys, customer journey maps, and quality function deployment (QFD) to collect and analyze customer feedback and translate it into process requirements and specifications.

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5 Benchmark and learn from best practices

The fifth step to continuous improvement is to benchmark and learn from best practices in the Six Sigma process design. You need to compare your process performance with the industry standards, competitors, or other organizations that excel in similar processes. You can use tools such as benchmarking studies, SWOT analysis, gap analysis, and site visits to identify and evaluate best practices and learn from their successes and failures.

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6 Review and update your process design

The sixth and final step to continuous improvement is to review and update your process design regularly. You need to monitor and measure your process outcomes, identify and implement corrective and preventive actions, and document and communicate your changes and improvements. You should also conduct periodic audits and reviews to ensure that your process design is aligned with your goals and metrics, customer needs and expectations, and best practices and standards.

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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?

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John Burke
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Carry out Pre build DFm and post build reviews. Carry out both Design as well as manufacturing process FMEA’s based on individual products (not a “boilerplate” to satisfy ISO) and update regularly with lessons learned. Create a live FMEA database so all new products have visibility to potential RPN numbers and lessons learned.

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What are the best ways to ensure continuous improvement in Six Sigma process design?

1

2

3

4

5

6

7

1 Define your goals and metrics

2 Implement the DMAIC cycle

3 Involve and empower your team

4 Adopt a customer-centric mindset

5 Benchmark and learn from best practices

6 Review and update your process design

7 Here’s what else to consider

Process Design

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What are the best ways to ensure continuous improvement in Six Sigma process design?

1

2

3

4

5

6

7

1 Define your goals and metrics

2 Implement the DMAIC cycle

3 Involve and empower your team

4 Adopt a customer-centric mindset

5 Benchmark and learn from best practices

6 Review and update your process design

7 Here’s what else to consider

Process Design

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