Every task requires a particular process. Where some jobs can be done in five processes, there are some which require fifty processes. Similarly, the process in Lean Six Sigma requires that five processes, usually, which cover:
- Reduction of Non-Value Added Leaps:
Production will need many steps. But if you give it a close look, there must be some steps that are not required or steps that can be reduced or conjoined. First of all, you need to create a graph of your present work process. Observe in how many steps your input gets the output. Then find out the steps that do not actually contribute and reduce them.
- Improving the Measurement System:
All the systems of measuring have variations. But it is necessary to evaluate the degree of variation each one produces for a particular result. The variations are usually small but there are bigger variations too and the companies sometimes do not pay attention to it. However, it is necessary as the output pays off the effort.
- Reduction of Common Cause Variation:
Out of the five ways talked, reducing common cause is the hardest one to accomplish. The thing is variations exist in all processes and it can be classified into common and special causes. The classification is based on how frequently a variation is observed. Common cause variation is measured on a regular basis. To reduce it, you need to classify your data to determine the amount of variation attributed to each factor and this should be done on the basis of process location, timing of shift, and type of order.
- Reduction of Special Cause Variation:
While the process containing common cause variation is considered stable, special cause variation is completely opposite to this. It causes a change in the process which can be both positive and negative. It is important to find out why the change has occurred. Reducing the special cause variation may result in an overall reduction in variation. Also, it can result in a more consistent process.
- Fixing the Mean Right to Improve Process Capabilities:
The first four ways mentioned are the key. This process is required just for the specification. As the process variation can be excessive, companies set up specification limits. If the mean is not fixed within the two specifications, the amount of rework will be larger as more values fall out on one side versus the other. For example, if the mean is at 54.75 instead of 55, it will cause in 28% of rework.
These five steps are the all-time recommendation by the EZsigma group. Understand them and apply them for better business outcomes.