How we can kick off and handle a process improvement initiative using Lean Six Sigma method. A handy reference as a memory capsule. Targeted audience: Business Analysts, System Analysts, Consultants, Lean Professionals, Project Managers and Leaders who do not wish to fall behind but make it better month over month. For more information please visit https://mitraz.com

1. Process
Improvement
Initiative
Increase Efficiency and
Profitability
By Anup Mitra
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Process Improvement Initiative

3. Recognize and Define
Strategic Objectives
Ways of achieving these objectives
Identifying gaps
Customer’s or end user’s opinion
SWOT Analysis
Benchmarking against competitors
Mission statement
Scope and Team - SIPOC
➔ Scope of the project
➔ Project team members
◆ Project Sponsor
◆ Stakeholders
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4. Recognize and Define - SIPOC
Define AS-IS and TO-BE (mission statement)
➔ Overall project definition
Supplier (of Input)
Inputs to ensure process works
Process or product
➔ Main steps of the process or using the
product
➔ Where we decide to start and end
Outputs of process or products
Customers for each output
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Force field
analysis
SWOT
SIPOC

5. Measure
Measure and understand the current process
Understand its performance
What is important for the customer
The problem and the potential causes
Critical factors
Capability to meet customer’s needs
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brainstorming
cause and
effect diagram
process
mapping/
flow chart
5W & 2H
data
collection
risk
analysis

6. Analyze
Review the process mapping
Analyze the data collection results
Establish current and future of probable improvements
Generate a list of critical factors that’s causing problems and waste
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measure analyze
charts
MS
Excel
other
analytical
tools

7. Improve
Maximize the process performance using list of critical factors
Generate possible solutions
Upgrade - improve ideas
Chose solutions, document complete solution
Experiment solutions
Implement or deploy
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brainstorming
regulations
effort
vs.
benefit
side
effects
complexity
time
Implementation
cost

8. Improve
Plan the change
➔ Steps, documentation, required resources, training, dates, roles and responsibilities
Execution, manage change
Make necessary adjustments throughout execution
Document procedures, best practices and process map
Test and retest in small phases and project moves forward
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to do list
poka yoke -
foolproof
project
management
tool

9. Control
Maintain gains obtained from improvement project by implementing monitoring procedures on
selective critical parameters.
Transfer required tools or tasks to the person responsible for the process in order to maintain gains.
Measure project performance through feedback and rating.
End of improvement project through
➔ Transfer of power
➔ Lesson learned
Financial evaluation and audit (benefits, control plan and process in place)
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10. Control - Control Plan
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variables to be
controlled for
customer
satisfaction
tools to
measure
periodic feedback
plan and
action/adjustments
automation
frequency
rapid response
plan to critical
controls
End of PI