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Does your data from yesterday represent the current state of your process better than that from a month ago? How can you place more emphasis on it yet still make use of older data? That’s what the Exponentially Weighted Moving Average does. 

Do you know the difference between tangible vs. intangible benefits? Measuring the results of your company’s output can be of vital importance. Understanding how these two measurements line up and differ from one another can help refine productivity. Additionally, failing to pay attention to these measurements could have serious ramifications. What Are Tangible […]

House of Quality? No, this is often referred to as a House of Pain because of the effort needed to complete one. Let’s see if we are just being overly pessimistic. 

Six Sigma at many organizations simply means a measure of quality that strives for near perfection. Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process — from manufacturing to transactional and from product to service.

Use this table to go between and convert Sigma to DPMO to Yield to Cpk.

Null hypothesis vs. hypothesis, which is the right choice? When you get into the different methods of analyzing data, there is no shortage of tools at your disposal. Understanding the difference between a null hypothesis and a hypothesis can make or break your testing and analysis stages. Let’s dive into both of these […]

Lean Six Sigma professionals, much like every other professional, love to talk in acronyms. The acronym of the day is DPMO. Let’s check out what it means.

Defects per opportunity, or DPO, refers to the number of defects that occur in relation to a given number of opportunities for which an error could occur. Let’s consider some of the benefits of measuring and monitoring DPO.

Flowchart vs. process map, what do you choose to use? When it comes to mapping out a project, you’ve got several choices on how to visualize them. If you’ve had trouble deciding on a format for your visualization, then read on. Today’s guide is meant to cast more light on these individual tools […]

What is rolled throughput yield? Your company has just announced that its product line has a 100% total throughput rate, touting it as a great win for everyone. However, from your perspective, you see massive amounts of rework being performed, disrupting the production lines, costing additional money, and impacting on-time delivery. If only […]

An organization may hear many voices (Customer, Business, Employee, and Process). It is the voice of the customer (VOC) that is the driving voice. Additionally, it is what should be important to the organization and what the organization should focus on. The satisfaction of the VOC needs to be balanced against the Voice […]

ZARA changes its clothing designs every two weeks, offering 11,000 distinct garments annually. In comparison, competitors change their designs every three or four months and produce 3-4,000 distinct pieces. This is fast fashion: the business model of replicating high-fashion, luxury-brand pieces quickly and cheaply, making them available to customers while the trend and […]

Is your data normal? If not, will that be a problem? It might be, since data normality can be important when using certain statistical tools to make your business decisions. 

Capability Indices How do you calculate capability indices? Capability analysis is an essential tool for statistical process control (SPC) and process improvement, applicable to a variety of environments from hospitals and labs to assembly and manufacturing. How to Calculate Capability Indices The formula for calculating a Cpk index is easily found: USL, upper […]

The Harada method helps individuals achieve self-reliance which in turn facilitates a company’s process improvement journey. Part One provides an overview of the method and its genesis. Subsequently, part Two presents five templates to use to plan a goal, measure the goal’s progress, and assess success. An example helps illustrate their practical use. […]

Process Work How do you measure process work? When first introduced in the 19th and early 20th centuries, time and motion studies established rules of motion that guaranteed optimal performance during a given period and reduced the number of movements needed to get work accomplished. Over the years, time and motion studies have […]

Quality is one of those words and concepts that have many meanings. Let’s review the concept and discuss the different definitions associated with the term. It refers to the degree of excellence or superiority of something, often concerning its intended purpose or function. Further, it is a measure of how well something meets […]

This article will introduce you to control limits. You will learn about the role of control limits, how they were designed, and the role they play in process improvement.

Six Sigma is a data-driven approach to quality, aimed at reducing variation and the associated defects, wastes, and risks in any process. This article explores the basics of Six Sigma process quality – definition and measurement. Defining Standard Deviation In a set of data, mean (μ) and standard deviation (σ) are defined as: […]

How do you convert DPMO to Sigma Level? There are several metrics you can use to measure how well your process is performing. Let’s look at three of them and discuss how to calculate them and how they relate. The three are DPMO, Sigma Level, and Cpk. Convert DPMO/Sigma to Cpk  Before discussing […]

In today’s fast-paced, technology-driven world, fostering a culture of innovation and agility is essential for startups that want to stay competitive. Startups thrive on innovative ideas, quick pivots, and the ability to adapt to change. This 2014 article raised awareness of Lean Startups. But creating an environment where continuous improvement and creativity flourish […]

Value stream map vs. process map, which is better for you? As with many tools and methods in Six Sigma, there isn’t a one-size-fits-all approach to mapping things out. Both of these tools have specific functions with some overlap. If you’re new to Six Sigma, then you’re in luck. Today, we’re going in-depth […]

Lean Startup methodologies have revolutionized the way modern entrepreneurs approach launching and scaling their businesses. At the core of Lean Startup is the idea of minimizing risk through rapid experimentation, customer feedback, and iterative development. This approach enables startups to efficiently test their business models and products with minimal resources while remaining adaptable […]

Root cause analysis (RCA) is a way of identifying the underlying source of a process or product failure. As such, then the right solution can be identified. RCA can progress more quickly and effectively by pairing an Ishikawa diagram. You can also use the scientific method in the form of the well-known plan-do-check-act […]

Never-ending improvement is the heart of any continuous improvement effort.  The Deming Cycle, or PDCA, is one of the first formalized approaches to utilize an iterative approach to improving processes, and it still serves as a fundamental tool today for continuous improvement.  This article will describe the stages of the Deming Cycle, the […]

You want to make good data-driven decisions, but can you trust your data? Is the measurement system you used to gather the data giving you precise and consistent measurements? A Gage R&R study will answer your questions. 

Repeatability vs. reproducibility, which should you use? Repeatability and reproducibility are two ways that scientists and engineers measure the precision of their experiments and measuring tools. They are heavily used in chemistry and engineering and are typically reported as standard deviations in scientific write-ups. While these two measurements are both used in many […]

Common cause vs. special cause variation, aren’t they the same thing? At first glance, you’d be allowed to think so. However, as with any part of the production cycle, there is a reason for these two measurements to exist. So, let’s dive right into what makes these variations different, and how to identify […]

Consider a power company for illustration purposes: A power company measures its performance in uptime of available power to its grid. Here is the five-step process to calculate your Process Sigma. Step 1: Define Your Opportunities An opportunity is the lowest defect noticeable by a customer. This definition, of course, is debatable within the […]

DMAIC refers to a data-driven quality strategy for improving processes, and is an integral part of the company’s Six Sigma Quality Initiative. DMAIC is an acronym for five interconnected phases: Define, Measure, Analyze, Improve, and Control.

Total Quality Management TQM is a management approach that originated in the 1950s and has steadily become more popular since the early 1980s. Total Quality is a description of the culture, attitude, and organization of a company that strives to provide customers with products and services that satisfy their needs. The culture requires […]

Is your data normal? Oh no! Is that a problem? The concept of data normality can be important when using certain statistical tools to make data-driven decisions.

What is non-normal data? Normally distributed data is a commonly misunderstood concept in Six Sigma. Some people believe that all data collected and used for analysis must be distributed normally. But normal distribution does not happen as often as people think, and it is not a main objective. Normal distribution is a means […]

How do you calculate the overall standard deviation of multiple groups or samples? You can’t just add them up and divide by the number of groups, like you do with averages. Let’s see how we can do it correctly.

Takt Time vs. Cycle Time: when do you choose what to use? Regardless of how efficient your processes are, you’re going to have to measure the time eventually. Now, if you’re a new Six Sigma practitioner you likely might be wondering about Takt Time vs. Cycle Time. Both of these metrics are important […]

Lean Six Sigma (LSS) is a structured approach that combines two powerful process improvement methodologies: Lean, which focuses on eliminating waste, and Six Sigma, which focuses on reducing variation and defects. When applied to the Environmental, Health, and Safety (EHS) function of an organization, Lean Six Sigma provides a robust framework for driving […]

Process time vs. cycle time is a discussion that comes up often for newcomers to Six Sigma. Understanding these principles and how they apply to your time management is vital. Failing to grasp these concepts can affect your bottom line negatively. What is Process Time? Process time describes the interval required for a […]

One of the most famous sayings in the Star Wars films is May the Force be with you. This saying may also apply to making changes in your organization. Let’s see what forces you need to identify and deal with when using a force field analysis to manage change.

The customer just called again, wondering if the item they ordered will be on time. Will it? Do your company’s processes make it possible to be on time per the customer’s needs? To know that requires understanding how long it takes to produce the product, and that requires knowing your cycle times.  An […]

What are the most common mistakes when using SIPOC? The SIPOC Diagram is one of the most useful tools in your arsenal when it comes to process analysis. It readily allows you and your team to grasp the various elements of a process before diving fully into detail on how everything fits together. […]

What is Gage R&R? Like it or not, any process is going to have variances and the potential for defects. Measurement error is unavoidable. There will always be some measurement variation that is due to the measurement system itself. Most problematic measurement system issues come from measuring attribute data in terms that rely […]

There never seems to be enough time on a project, especially when considering flow time vs. cycle time. These measurements are great ways of tracking time throughout a project. However, when to use these respective measurements comes down to the stage of the project. Don’t fret, we’ll get you up to speed in […]

There are three measures of central tendency for data. One is the mean or x-bar, and the others are the median and mode. When you’re diving into statistical analysis, these are basic components. Most practitioners should have encountered these in grade school, but a refresher never hurts. Let’s dive into what it means. […]

One of the best ways to introduce people to new concepts is through a hands-on, team experience. Better yet, a game! Dig out some Legos and let the Lean Lego Game begin!

When learning about Six Sigma, it may help to consider these charts. These detail how Sigma Performance Levels relate to defects per million opportunities (DPMO), and some real-world examples. Sigma Performance Levels Table Sigma Performance Levels – One to Six Sigma Sigma Level Defects (or Errors) Per Million Opportunities (DPMO) Yield (or Produced […]

Full factorial DOE is one of the most powerfully designed experimentation statistical tools for understanding the impact your process inputs have on your process outputs. 

So what is the real difference when looking at Cpk and Sigma Level? If you’re new to Six Sigma, there is no shortage of acronyms and calculations to keep in mind as you work on your knowledge base. Both Cpk and Sigma Level are valuable tools when looking at your processes and production. […]

In the fast-paced world of startups, flexibility is crucial. Entrepreneurs often enter the market with bold ideas, but reality has a way of testing those ambitions. As conditions change, so must the strategies. This adaptability is known as a pivot—a fundamental shift in a startup’s business model, product offering, or market approach. Pivoting […]

Upper Control Limit Overview: What Is the Upper Control Limit (UCL)? A control chart consists of several parts. It has two control limits and an average line. The bottom dashed line is called the lower control limit (LCL).  The solid middle line is the average of the statistic being plotted. The top dashed […]

When you know your process yield (percentage of a process that is free of defects), you can use this yield to sigma conversion table to easily determine your process sigma level, as well as your process defects per million opportunities.