A common question I hear is "what if my company doesn't support process improvement?" I share 4 main approaches you can take to deal with this situation, instead of feeling frustrated by it. Links LeanSixSigmaHomes.com BIZ-PI.com Creative Safety Supply Have a question? Submit a voice message at Anchor.fm...
I share my experience getting my first COVID-19 vaccine shot, and how I analyzed that process from a lean perspective. I found that there was only one second of value, compared to a process that took me over an hour to complete. On a related note, I also have some links to lean applied during the pandemic on my website (see links below). Links Applying Lean Methods to Mitigate COVID-19 at Work BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm...
I was recently asked about the difference between PDCA and PDSA. I had heard some new information from another podcast, and dug into one of the references to learn more about it. In this episode, I read through a paper from Ronald Moen that provides a good historical perspective. Note: I mispronounced Charlie Protzman's name in the audio. Apologies! Links Foundation and History of the PDSA Cycle - Ronald Moen Podcast Interview with Charlie Protzman and Patrick Adams BIZ-PI.com Creative Safety Su...
A recent Value Stream Mapping event was held virtually, and we received some positive feedback from the event attendees. I wanted to share some of the comments to show how process improvement helps much more than just faster processes with less quality issues. It helps engage employees in the future direction of the organization, builds teamwork across departments, and creates a safe space for discussing problems and challenges. Please contact me if you'd like help with facilitating your own lea...
Does your organization use a structured problem solving process, like DMAIC, 8D, or PDSA? If no, why not? I share my views on what challenges are created when you don't have structure to your problem solving approach. Links BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm...
Are you trying to decide how to select the best projects to work on, but have many stakeholders and customer needs to consider, and too many project ideas? Check out the Project Prioritization Matrix to help you objectively evaluate these projects and select the ones that meet the most important criteria. I pulled the audio from the training video for you to listen to in this podcast. There is also a link to the video if you had trouble following along, and I provide a link to the template you c...
I received a question today that I thought would be helpful to everyone: “Imagine you are getting ready to kick-off the value stream workshop and you start to receive emails from a bunch of different people in the organization asking to attend. What would be your response?” I answered the question in an article on my website, but I wanted to read my response for this podcast. Links Article: How to decide on the right number of people for your lean event? BIZ-PI.com LeanSixSigmaDefinition.com Cre...
When making improvements to a process, cost savings and avoidance is a common outcome that is estimated and reported. A common error is to combine the data together into one overall number, but they should be separated into three distinct buckets of money: Income Statement, Cash Flow and Growth. Links Article: Client saved $800,000 in 3 Days E2: What is the difference between hard and soft financial savings? BIZ-PI.com LeanSixSigmaDefinition.com Creative Safety Supply...
One of the most impactful quality initiatives I was involved with was the creation and deployment of the Cost of Nonconformance (CoNC) report. It was a method to assign a dollar amount to quality problems in order to bring attention to management in the language they most often respond to, money! It could also be applied more broadly beyond just quality issues to any type of waste to increase visibility for your Lean or Six Sigma initiative. Check out our Cost of Poor Quality course at https://w...
In process improvement, there is a strong focus of data. But in order to analyze data for an improvement project, you need to know what type of data you have or need, so you can perform the correct analysis. I share the different types of data you may encounter for your project. Links BIZ-PI.com LeanSixSigmaDefinition.com
I saw a recent question in a forum, asking about the origin of the sample size of 30 data points. I decided to read you the response I gave, and make it a new blog post on my website. Links Article: Why do we need 30 data samples? BIZ-PI.com LeanSixSigmaDefinition.com...
I share an article I wrote back in Dec 2013 about reducing or eliminating test or inspection steps using Six Sigma analysis methods of capability and stability, along with risk mitigation tools like FMEA and error proofing. Links Article: Top 3 things to validate before removing test or inspection steps Article: Which Should You Use Cpk or Ppk? BIZ-PI.com LeanSixSigmaDefinition.com...
I share an interview I did with Mark Graban about why I created this podcast. He included me in a new networking group called Lean Communicators. We are a group of podcasters that talk about Lean, and we meet about once a month to discuss best practices and learn from each other. Check out the website of all the contributors at LeanCommunicators.com , where you can subscribe to an email list of new episodes from all contributors, or subscribe to individual podcasts. You can also follow us on Lin...
Most people calculate the average when summarizing data, but what about the median? The median is not as sensitive to outliers and skewed data, and can be a better indicator of the typical or most common outcome in your data. Links Wikipedia: Median BIZ-PI.com LeanSixSigmaDefinition.com...
Do you see problems recur later after all the attention has gone away? That could be the Hawthorne Effect at work, which can create confusion on whether your improvements are actually working. Links Wikipedia: Hawthorne Effect BIZ-PI.com LeanSixSigmaDefinition.com...
When I facilitate mapping events, after completing the current state map and before we create the future state map, I like to first walk the team through an ideal state discussion. I categorized these concepts and share the list with you in this podcast. Links Why I like using the Ideal State Mapping approach BIZ-PI.com LeanSixSigmaDefinition.com...
Ground rules are an important element of running a successful process improvement event (called Kaizen Blitz or Kaikaku events). In this podcast, I share a compiled list of rules that you can use as a starting point for your next improvement workshop. Links List of Typical Lean Kaizen Event Ground Rules BIZ-PI.com LeanSixSigmaDefinition.com...
During some recent travel, my wife and I ended up watching multiple episodes of "Bar Rescue." I've watched the show for many years, so I re-watched it with a new lens, now that I'm consulting on my own. As I thought about my approach to consulting, how would I help these bars and restaurants make dramatic improvements? Listen for my comparison of how I would prefer to help these bars versus the approach used by host Jon Taffer. Links JonTaffer.com Bar Rescue Show BIZ-PI.com LeanSixSigmaDefinitio...
I discuss the Lean approach to writing a book, which is how I published my first 2.5 books. LeanPub.com allows you to write and publish your book for free and release similar to software, instead of one large batch like in traditional book publishing. Links LeanPub.com Lean Six Sigma for Good: How improvement experts can help people in need, and help improve the environment Lean Six Sigma for Good: Lessons from the Gemba (Volume 1) Lean Six Sigma for Good: Lessons from the Gemba (Volume 2) BIZ-P...
I discuss the internal Lean Six Sigma certification program I helped develop and implement at Rockwell Collins (now Collins Aerospace), and why I think it's a good model for other organizations to consider if you want to offer certifications. Links BIZ-PI.com LeanSixSigmaDefinition.com
If you've struggled to decide what improvement project to work on at work or for a certification project, check out this list of project or event ideas that you could consider for your industry. I have examples from the following categories: Personal Life, Finance and Accounting, Human Resources, Sales, Shipping/Receiving and Warehouse, Information Technology (IT), Product/Service Design, Call Center, Healthcare, Manufacturing, Sports, Grocery/Supermarket, Nonprofits, Environment, Corporate Resp...
I try to simplify some confusion about the 7 types of waste (or are there 14 types?), the 3 M's, and explain simpler ways to think about opportunities in a process. Links Article: From 7 Wastes to 3 – The Yamada Method Acronyms for remembering the wastes BIZ-PI.com LeanSixSigmaDefinition.com...
I finished writing an article about two sustainability certification programs that require continuous improvement, but don't give guidance on how to do that. I explain why I think Lean is the best method to adopt for these mission-driven organizations. I also share examples below in the links about why I think Toyota is a leader in community engagement and environmental causes, not just financial performance. Links Article: Continuous Improvement key to B Corps, Fair Trade and other mission-driv...
I had a call this week helping out with a Black Belt project, and I was reminded about the Standardize-Do-Check-Act model that should be implemented first, before trying to make improvements to a process using the PDCA model (Plan-Do-Check-Act) Links BIZ-PI.com LeanSixSigmaDefinition.com Kaizen - The Key to Japan's Competitive Success by Masaaki Imai Photo from Masaaki Imai's "Kaizen" book about SDCA and PDCA...
I received two questions from Mark Graban about my first episode. He is a well-known Lean consultant with expertise in the healthcare industry, and has authored multiple books, including Lean Hospitals and Healthcare Kaizen and Measures of Success. He is also the host of multiple podcasts, including Lean Blog and My Favorite Mistake. Learn more about him at MarkGraban.com Links BIZ-PI.com LeanSixSigmaDefinition.com Episode 1: Why are Six Sigma Black Belts paid so much? MarkGraban.com...
During Lean and Six Sigma classes, I meet a lot of people who are good problem solvers already, and they mention that the topics are similar to how they approach problems. Here are some of my observations about my interactions with them, and what takeaways I gathered. Links BIZ-PI.com LeanSixSigmaDefinition.com
I share exciting news that we have digital access to Norman Bodek's past PRODUCTIVITY newsletters from 1980-1993 . He lived in Vancouver, Washington (near Portland), but was moving to Japan permanently, and we have scanned in the documents for you to search, download and review. Links BIZ-PI.com LeanSixSigmaDefinition.com PRODUCTIVITY newsletters and interviews with Norman Bodek...
I discuss the simple visual management templates called SQDC (also called QDIP). These visuals help simplify the daily management for a process area, to quickly bring attention to areas that need help. A video of the discussion is available on the product page in the link below Links BIZ-PI.com LeanSixSigmaDefinition.com Watch a video or download the SQDC templates...
I discuss the Lean at Home contest being run by Lean Portland. We are giving away $200 in prizes to those who submit an improvement project at home that was completed in the last 6 months. We also have a free online course you can take if you need some help! Links BIZ-PI.com LeanSixSigmaDefinition.com "Lean at Home" contest "Lean at Home" - Free online course...
I explain what Pareto charts are, and why they should be used more often than they are. I also summarize an older article I wrote about changing the way to display these charts. Links BIZ-PI.com LeanSixSigmaDefinition.com (Pareto) New spin (literally) on an old quality tool...
