Maintain the Gains

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I saw this statement on the web today and thought I would address it's comment about the lack of systematizing, tracking and sustaining gains.

"Many organizations use Six Sigma methodologies to identify, define and design business processes. Through their work they render processes more effective, efficient and predictable. But some let off the gas pedal when it comes to systematizing, tracking and sustaining the efficiencies gained."

Whether you are doing Lean Six Sigma or just Six Sigma you should be still using the DMAIC 5 step process. The last step is control where you place on the new process controls to maintain the gains. I'd say that those lifting off the gas pedal are stopping after the improvements are in place. They probably are not aware of the DMAIC process and thus did not implement the controls.

So what type of contols are there that one could implement after they have made improvement to a process? Here are several listed below:

1. (THE BIGGEST) revised standard procedures. Written procedures are so important to controlling a process.

2. Run Rules – Standard procedures have the details but posted should be a one page set of what I call run rules. These are key step to remember while doing the job. This is a sheet that even the “old-timers” regularly refer to in doing their job.

3. Contingency plan – This is a needed item in the control phase of any project as NOTHING goes perfect the first time. This tells people what to do when things go “bump in the night”. If you do not have this, when things go wrong (and they will) everyone will go back to the old way. Why because they know how to solve the problem in the old way and they are not sure in the new way.

4. Visual Controls – These we deal with everyday. The start button in the computer screen is a form of visual control. The Gas Gauge in your car is a visual control. Changed process the team needs to thing of thing that visually will help people do the right thing. Just like the Orange doily under the Decaf coffee.

* Mistake Proofing – is a type of visual control that only lets a person do the thing the right way. Kind of like a jigsaw puzzle the piece only goes in one way.
* Go No Go Gauges – These are used a lot in manufacturing where they use them to check if something is the correct size.

5. Setup Approvals – Some times you need some on to review and approve how thing are set up. I try to avoid this one but doing controlling the process with one of the above but if this is the only way then do it.

6. Periodic Audits – Audits are always good. They let you see how things are really done. Then you can review the findings and adjust the procedure or retrain the people.

7. Binning – This is just plan sorting things into similar groups.

8. Control Charts – If all else does not seem the right way then control chart the step. There are all kinds of control charts some easy to do some hard but all work when used properly.

Peter Bersbach
Six Sigma Master Black Belt
Bersbach Consulting
From Process to Profits
1.520.829.0090