PROJECTS – Six Sigma is a toolset introduced by engineer Bill Smith while working at Motorola in 1986 and has the objective to reduce variation in business processes. Based on advanced mathematical statistics it seeks to remove defects by eliminating root causes and controlling the inputs in order to influence the outputs.
Lean is a systematic method for waste minimization and continuous improvement. This management philosophy is derived mostly from the Toyota Production System (TPS) and identified as “lean” only in the 1990s. The Lean tools go hand in hand with Six Sigma tools with the sole goal to stabilize, improve and sustain quality, delivery and cost. It is a common misjudgment to consider Lean applicable only in production. Wherever there is a process, there is variation and waste.
The Solutions Ahead approach to Lean and Six Sigma projects is based on DMAIC (Define, Measure, Analyze, Improve & Control) and PDCA (Plan, Do, Check, Act) methodologies. Although training for involved professionals and teams might be part of the projects in order to ensure the sustainability of implemented tools, it is not the target. The target is to improve your process and to grow your business with an unwavering focus on your customers. Our contract will be indeed a Project Charter through which we commit to clear targets that need to be achieved based on the problem statement, project scope, involved teams and available resources. This is how we guarantee our work.
Organizational Design / Development (OD) – These projects are targeted to create organizational stability and prepare the culture for future changes. Jay Galbraith developed his “Star Model™” framework for analyzing organizations in the 1960s. Ever since, organizations have been using this model to create teams or improve structures to ensure the company has in place the right strategy, solid structures, stable processes, the right people with the right skillset and the best metrics and reward systems to measure and celebrate successes.
All projects contracted with Solutions Ahead are driven where the work is happening, so at the location of our client, since they are based on observation and thorough analysis. We are going to join you and work together to help you achieve your goals and we guarantee our work.
Goal: Improve business processes using Lean and Six Sigma tools in order to achieve better quality, delivery and cost, customer satisfaction and ultimately organizational growth and increased profitability.
Project architecture: All projects will start with the clear definition of the problem statement, what needs to be improved and the scope of the project (which processes will be improved). Additionally, we will define as part of our contract the targets, the project team, needed resources and timeline.
For complex organizational process improvement projects, we will use the DMAIC approach:
| Phase | Target |
| Define | Define project, its scope, target, resources, information, team and timeline |
| Measure | Map the current state of the process, collect data, funnel information and identify gaps and bottlenecks |
| Analyze | Based on the phase II data identify what causes the problem, apply statistical tools to ensure robustness |
| Improve | Create stability and create solutions to reduce variation and eliminate waste to improve the process |
| Control | Sustain the solution through standardization and continuous improvement |
For simple process improvement projects, we will use the PDCA approach:
| Phase | Target |
| Plan | Define the problem, the actions needed to solve it, expected outcomes, responsibilities, resources and timeline |
| Do | Brainstorm and implement improvement actions, run the process several times and collect data |
| Check | Based on the results of the implemented actions verify the outcome and compare with the expected outcomes |
| Act | If expected outcomes are met: validate and standardize
If expected outcome are not met: adjust the actions or expected outcomes and go to Do phase |
Lean tools: 5S, Andon, Bottleneck Analysis, Gemba, Heijunka (Level Scheduling), Jidoka (Autonomation), Just-In-Time (JIT), Kaizen (Continuous Improvement), Kanban (Pull System), KPIs (Key Performance Indicators), Muda (Waste Elimination), Overall Equipment Effectiveness (OEE), Poka-Yoke (Mistake Proofing), Root Cause Analysis, Single-Minute Exchange of Dies (SMED), Standardized Work, Takt Time, Total Productive Maintenance (TPM), Value Stream Mapping, Visual Management, Activity of X, Process Mapping, Spaghetti Chart, Time Value Map, VA / NVA Analysis, Load Chart, Cause and Effect Matrix, Set Up / Change Over Reduction, FMEA (Failure Modes and Effects Analysis), Strategic Inventory / Buffer.
Six Sigma Tools: Statistical and fitting tools (Analysis of variance, General linear model, ANOVA Gauge R&R, Regression analysis, Scatter diagram, Chi-squared test), SIPOC, 5 Why Analysis, Fishbone, DOE (Design of Experiment), QFD (Quality Function Deployment), Pareto Analysis, Control Charts, Control Plans.
All projects will be delivered where the process is running. The projects will have a built in communication plan to ensure constant progress reporting towards your management team. Solutions Ahead guarantees it’s work through committing to the expected results in the project charter. The results of each project will be monitored for e defined time after the project will be considered closed to ensure sustainability and continuous improvement of results.
Goal: To create stability in the organization and to prepare the company for upcoming changes and transformation.
The OD projects are being delivered based on the work and research of Jay Galbraith. It implies the analysis, measurement and definition or improvement of 5 organizational aspects: Strategy, Structure, Processes, People and Rewards.
The architecture of the projects is: Project Charter – Current State – Future state – Brainstorming – Action Plan – Implementation – Assessment.
All projects will be delivered where the process is running. The projects will have a built in communication plan to ensure constant progress reporting towards your management team. Solutions Ahead guarantees it’s work through committing to the expected results in the project charter. The results of each project will be monitored for e defined time after the project will be considered closed to ensure sustainability and continuous improvement of results.