The Keys to Defining Process Solutions

Once a thorough examination of current practices has been made and relevant data collected, the focus of a lean Six Sigma transition turns to defining solutions to any issues uncovered. These solutions could range from production floor layout changes to the addition of a feedback form to a customer service packet. To successfully define process solutions that eliminate waste, improve quality and meet customer standards in any company, specific elements must be in place :

  • The issue requiring attention must be clearly defined.
  • A capable team invested in the process is assembled.
  • The team works through the process of defining solutions as a unified entity.
  • Accepted design techniques are applied.

Defining the issue

Before a solution can be created, the target issue and desired outcome must be identified. This information should be detailed in an action plan and made accessible to the team responsible for working up a solution. Specifics must be defined in order for the plan to be useful, however. For example, a plan aiming to create a lean manufacturing Six Sigma environment should specify an exact number of defect-free units as the monthly production goal. This is a more meaningful goal that the blanket statement 'production should be increased'.

Preparing the team

Members of the solution team should be well versed in the process requiring improvement, but they will need additional skills in order to create a workable, effective solution. Team leaders must determine from what additional knowledge members would benefit, such as process modeling and business process reengineering, and arrange for training before the project begins.

Uncovering options

Although team members feel ready to create solutions right off the bat, the first task is for each member to move away from the comfort zone of their specialized knowledge. As a whole the group must learn to see the gathered process data from a variety of perspectives. From considering a process's outcome as it effects a customer or an employee further down the production line, the team is enabled to develop more creative lean Six Sigma process solutions.

Defining a solution

The process of solution development includes a series of five steps. The team reviews data gathered during the lean Six Sigma evaluation phase and determines the impact upon the organization's overall performance. It may be found, for example, that a particular service practice is linked to an unacceptably high number of customer complaints and closed accounts. From this point, the team evaluates the pros and cons of possible solutions. Considerations should include expected resistance to process changes, financial impact and expected effect upon overall quality. After evaluating the options, the team determines the best choice and specifies the details of the new process and how best to implement it.