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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.

Successful initial implementation and ongoing maintenance of process improvements requires overcoming the resistance to change. Green Belts are change agents who need to recognize, understand, and interpret resistance to change and develop skills to manage it effectively. Managing change resistance is often covered in training, yet a primary learning issue facing most organizations […]

With ever more complex products, processes and services the potential for high impact failure modes increases. Risk management is crucial for business success and the calculation of Risk Priority Number with mitigation and correction actions is an industry standard methodology that helps achieve your quality goals.

You are often faced with many options on how to improve the process. Which one is the best? The Pugh Matrix is a simple tool for you to decide which approach — or hybrid of approaches — you should use.

Data analysis is a fundamental process in any project. However, data can be lumped into different types, with categorical and continuous data seeming almost opposed at first glance. That said, mastering these data types and understanding when and where to use them can lead to far more precision during data analysis as a […]

In the world of startups and product development, the Minimum Viable Product (MVP) has become a cornerstone of agile innovation. An MVP is a product with just enough features to attract early adopters and validate a product idea. It allows businesses to test their hypotheses and gather valuable feedback without expending excessive resources. […]

Throughout any project, you’re going to gather up quite a bit of data. Now, this can be broken down into two categories: variable and attribute data. Understanding the difference and learning how it is applicable during the analysis stage can be crucial for future decision-making. So, with that in mind, let’s take a […]

Continuous improvement specialists are challenged to solve problems for their organizations or clients. They have acquired a wide array of tools, methods, and techniques for that purpose. If continuous improvement practitioners can establish the winning conditions for change, they can look forward to successful outcomes. However, the devil is in the details, making […]

In today’s competitive business environment, maintaining a high level of quality has become vital to a company’s success. It is imperative that suppliers provide quality parts that meet customer requirements the first time and every time. 

Residual, standardized residual, studentized residual — what do they mean, and how do I use them? 

ANOVA will tell you whether there is a statistically significant difference in the population means of three or more groups of data. But which means are different? Tukey’s will tell you that. Analysis of Variance (ANOVA) is used to determine whether the population means of several sample data sets are statistically different or […]

Critical of quality is the path to customer satisfaction. Learn how Critical to Quality impacts the ability to satisfy your customer, the benefits of addressing CTQ related issues, and see an example.

Control charts have two general uses in an improvement project. Undeniably, the most common application is as a tool to monitor process stability and control. A less common, although some might argue more powerful, use of control charts is as an analysis tool. Throughout this guide, you’ll have the various control charts identified. […]

If you haven’t paid attention to the news over the last two years, you’ve likely missed the buzz surrounding AI. Artificial intelligence has touched down in a big way over the last couple of years. Products and services like ChatGPT, Midjourney, and Google Gemini have entered the cultural zeitgeist. Now, that’s fine and […]

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

Whether you are talking about the F-value, F-test, F-statistic or F distribution they all revolve around the same concept of using variances to make statistical decisions about your data.

Asking “Why?” may be a favorite technique of your 3-year-old child in driving you crazy, but it could teach you a valuable Six Sigma quality lesson. The 5 Whys is a technique used in the Analyze phase of the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology. It is a great Six Sigma […]

Are you confused yet? Is it the 6 Ms? Is it 5 Ms and a P? How about 4 Ms, 5 Ms or 8 Ms? Let’s explore some of these and figure it out.

Creating and mapping business process models can sound like a daunting task with little tangible value. With input-process-output models, we debunk these myths and introduce a versatile, straightforward methodology that can be used to transform your business.

The seven basic tools in my home tool chest are a hammer, screwdriver, wrench, saw, drill, pliers, and duct tape. What basic QC tools do you have in your continuous improvement tool chest? Let’s check it out.

There are a few different ways you can improve a process in your business. Before you get to work with implementing these changes, it does help to visualize the entire thing. A SIPOC diagram is a highly useful tool for mapping out the steps of a process. Processes and projects are complex, but […]

FMEA — failure mode and effects analysis — is a tool for identifying potential problems and their impact.