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A Simple Approach to Continuous Improvements

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.
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A Simple Approach to Continuous Improvements

  1. 1. Process Improvement Initiative Increase Efficiency and Profitability By Anup Mitra 1
  2. 2. D E F I N E M E A S U R E A N A L Y Z E I M P R O V E C O N T R O L 2 Process Improvement Initiative
  3. 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 3
  4. 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 4 Force field analysis SWOT SIPOC
  5. 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 5 brainstorming cause and effect diagram process mapping/ flow chart 5W & 2H data collection risk analysis
  6. 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 6 measure analyze charts MS Excel other analytical tools
  7. 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 7 brainstorming regulations effort vs. benefit side effects complexity time Implementation cost
  8. 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 8 to do list poka yoke - foolproof project management tool
  9. 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) 9
  10. 10. Control - Control Plan 10 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