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When a product or service fails to meet quality standards, there are costs associated called Costs of Non-Conformance, or CONC. Find out more about this SixSigma concept.

Standard operating sheets help keep operations running smoothly. They outline the process steps, timing, and other elements of a given operation and allow employee engagement in the process.

As artificial intelligence (AI) continues to reshape industries, organizations are increasingly integrating AI-driven solutions into their continuous improvement programs. AI has the potential to revolutionize these programs by automating repetitive tasks, uncovering patterns in data, and offering predictive insights that can accelerate decision-making. However, AI’s implementation introduces new considerations for businesses aiming to […]

One of the most confusing issues associated with someone saying “I’m using Six Sigma” has to do with what methodology they are using. A majority of the time they are using the DMAIC methodology because they have existing processes that are wasting resources (hence the big savings you’ve heard about at GE, Honeywell, […]

Get a quick primer on Paynter charts, a graphical method for comparing data regarding sub-groups. We look at how Paynter charts compare to KPI data and Pareto charts as well as the benefits of creating and reviewing Paynter charts.

It is important to have a procedure in place to finalize a project. That is where a PSO (process sign off) procedure comes in.

With the right metrics, SQDCM (safety, quality, delivery, cost, morale) boards can – and should – be used on the floor to enhance strategic development and the power of your Gemba walks.

The term COC can mean two different things in Lean Six Sigma management. It can either refer to the “cost of conformance” or a certificate of conformity. Since “cost of conformance” has already been defined on isixsigma.com at the link listed above, this article will discuss certificates of conformity. What Is a Certificate […]

The only acceptable quality level should be zero defects. But that’s not always the case. Let’s learn what an acceptable quality level or limit is all about.

You have probably heard of the acronym PDCA (Deming Cycle) but have you heard of FOCUS PDCA? Read this article and you will understand what it is.

Making data-driven decisions is critical in today’s business environment, but can you trust your measurement system to give you meaningful data? Measurement System Analysis is the tool you need to know whether you can trust your data.

Is assignable cause a bad thing? No, it’s a signal something happened in your process that you didn’t expect. It could be good or bad, but you should find out what happened.

What ethical challenges does AI pose? Anywhere you look now, there is no shortage of artificial intelligence systems in workplaces around the world. For some companies, this comes down to multiple systems working in concert with one another to achieve goals. Many industries have embraced AI, but that doesn’t mean it is a […]

There are times when you may encounter the need to analyze non-normal distribution. Having another option other than the ANOVA test in these types of situations is critical.

Many statistical tests have underlying assumptions about the population data. But, what happens if you violate those assumptions? This is when you might need to use a non-parametric test to answer your statistical question. Non-parametric refers to a type of statistical analysis that does not make any assumptions about the underlying probability distribution […]

Your customers often ask, “When will I get my widget delivered?” You respond with, “It depends.” If you know your turn-around time, you might be able to provide a better answer. Let’s learn more about turn-around time.

Your business is at war with waste, defects, and inefficiencies. Let’s attack and defeat your enemy with a lightning-quick attack using overwhelming forces. In other words, a Kaizen Blitzkrieg, or Blitz for short.

I will be the first to admit that I still have a few cases of 8-track tapes. For those too young to know what 8-track tapes are, please ask your parents. As a customer who purchased a lot of music, my needs were simple. I wanted a clearer sound and something smaller to […]

Voice of the Process vs. Voice of the Customer isn’t a debate necessarily. In Six Sigma, many voices communicate concepts, ideas, and progress that any organization should pay attention to. Some, like VOP, can inform you of the progress of a process. However, others like VOC, serve as a beacon into the minds […]

In the Six Sigma quality methodology, process performance is reported to the organization as a sigma level. The higher the sigma level, the better the process is performing. Another way to report process capability and process performance is through the statistical measurements of Cp, Cpk, Pp, and Ppk. This article will present definitions, […]

We have all heard the phrase “garbage in, garbage out.” AOQ is defined as the expected average quality level of an outgoing product for a given the value of incoming product quality. 

Fishbone diagrams are used to drill down to the root cause of a problem. The diagram looks like the bones of a fish, where each main bone represents a possible category of root cause, and subsequent drilling down is shown as smaller and smaller bones.

In Six Sigma, you will often hear the phrase, “It worked so well we stopped doing it.” The purpose of a process control plan is to maintain the gains of your project and prevent this from happening. 

Waste is all around your organization. Using the acronym TIMWOOD, you will learn how to identify the 7 wastes of lean and eliminate them to improve your organization.

The purchasing department manager left another message, informing the planning department that they once again sent over a request for a quote that didn’t contain all the information needed to place the order.  It’s a problem that seems to keep repeating, but is it truly that impactful an issue? To better understand the […]

When a company promises and delivers on quality, there is a good chance that customer satisfaction and retention will be high. But paving the road to success depends on companies being well-informed about their own business. They achieve that knowledge by developing and utilizing effective metrics. Why Do We Need Them? Metrics are […]

Remote work has been around for years now. However, the recent COVID-19 pandemic showed the flexibility of working from home for some of your team members. With that in mind, we’re going to take a deeper look at remote work, some of the current trends driving it, and the benefits and drawbacks it […]

When you have multiple factors at different levels, it can be challenging to figure out which is the optimal combination. Design of Experiments is one common method you can use. The Taguchi Method is another.

When it comes to getting a task accomplished, having an operations process greatly increases the probability of success.

Repeatability vs. precision, how do they apply to your workflow? Six Sigma is filled with different tools, terms, and methodologies applied across the production line. Today, we’re looking at two core concepts that deal with the accuracy of your processes. What Is Repeatability? Repeatability is the typical variation that occurs when a person […]

The Robust Design method, also called the Taguchi Method, pioneered by Dr. Genichi Taguchi, greatly improves engineering productivity. By consciously considering the noise factors (environmental variation during the product’s usage, manufacturing variation, and component deterioration) and the cost of failure in the field the Robust Design method helps ensure customer satisfaction. Robust Design […]

This article will introduce you to special cause control chart patterns. You will learn why special cause variation is one of the foundational concepts in quality improvement and the use of special cause variation in process improvement.

6W? 5W1H? 5W? The bigger question is, how do you make sure you’re asking the right questions to guarantee you properly solve your problem or execute your project?

Plackett-Burman experimental design is used to identify the most important factors early in the experimentation phase when complete knowledge about the system is usually unavailable. Developed in 1946 by statisticians Robin L. Plackett and J.P. Burman, it is an efficient screening method to identify the active factors using as few experimental runs as […]

The two-sample t-test is one of the most commonly used hypothesis tests in Six Sigma work. It is applied to compare the average difference between two groups. You use it to determine if the difference is significant or if it is due instead to random chance. It helps to answer questions like whether […]

Do you know how to account for the margin of error in your customer surveys? A survey is a valuable assessment tool in which a sample and information relate to a larger population. Surveying is like tasting a soup, a few spoonfuls tell what the whole pot tastes like. An Example of Margin […]

How do you implement the Six Sigma methodology? Consider the 5W1H approach when implementing it for your organization. 5W1H (who, what, where, when, why, how) is a method of asking questions about a process or a problem taken up for improvement. Four of the W’s (who, what, where, when) and the one H […]

Lead time vs. cycle time, which do you choose? Improving your processes is a nuanced and complicated thing. Understanding the difference between the various measurements of time can only benefit your workflow. So, let’s dive into what this means and how it applies to your production. What is Lead Time? Lead time is […]

What is poka-yoke? Have you ever accidentally microwaved your face? No? You’ve never opened the microwave door while it was cooking and accidentally exposed your face to microwave energy? I know that you haven’t because whenever you open the door, the microwave stops running. There is a switch that triggers when the door […]

The upper specification limit represents the highest limit that a measurement or reading can reach and still be acceptable to the customer. There are several benefits of monitoring USL and determining if a process can satisfy customer requirements.

Why is 6 sigma 3.4 ppm, not 2 ppb? The calculation of process sigma after a process improvement project should be reported as short-term sigma.

Do you hear voices? In a business context, that’s normal. Let’s listen in to the voice of the business and hear what it has to say.

The word Normal generally has a positive connotation. When applied to statistics, the term Normal Distribution has essentially the same effect. Let’s see why. 

Out-of-control Action Plans (OCAPS) are a piece of the Lean Six Sigma methodology that is often overlooked. Though they have been phased out in some organizations, it is important to understand their purpose and how they can help a company improve its processes.

Non-value-added is the work your customer is not paying you to perform.

Cp is one of the metrics calculated for determining whether your process is capable of meeting customer specifications or requirements. It is useful in comparing different functions and their ability to meet their unique specifications.

Do you feel that implementing change in your organization is going too slowly? So did Jack Welch of GE, which is why GE developed the Change Acceleration Process (CAP). Let’s explore how the concepts of CAP might help your organization.

Cycle time vs. throughput time, do you know the difference? Typically, when we look at the steps of our workflow, you’ll want metrics to gauge effectiveness and efficiency. Depending on the scenario, you’ll want to use one of these two metrics while looking at the work time needed to complete a deliverable. What […]

As competitive and market pressures increase, having a clear understanding of product reliability, service life, and expected failure rate is crucial. We explore how by utilising B10 life, we can optimise our product development and satisfy our customer requirements.

Statistics is a branch of math that involves the collection, description, analysis, and inference of conclusions from quantitative data. But what is a statistic? Let’s find out. The word statistic is a word with numerous possible definitions. In its simplest form, a statistic can be defined as a descriptor of a set of […]