• Using the Theory of Constraints to Choose Six Sigma Projects

    Using the Theory of Constraints to Choose Six Sigma Projects

    The theory of constraints helps pick winning projects. If you choose the wrong projects it’s possible to make big “improvements” in quality and productivity that have absolutely no impact on net profit. One approach uses the theory of constraints (TOC) to determine which project(s) to pursue. Every organization has constraints, which come in many forms. […]

  • Human Metrics in Six Sigma

    Human Metrics in Six Sigma

    Six Sigma teaches us to view everything as a process. We should take an objective look at the system, measure the values, form a model, enact changes on the process, and observe the effects of these changes. However, we sometimes want to measure objectively something that is intrinsically subjective, the opinions of people. These fall […]

  • Six Sigma: Love It or Hate It?

    For a technical topic, Six Sigma tends to generate a lot of strong feelings. As the author of The Six Sigma Handbook I obviously have a few of these feelings myself. Still, on balance, I’m a Six Sigma “lover.” I think that the approach is an excellent way to help organizations achieve their goals by […]

  • Six Sigma, Data Mining and Dead Customer Accounts

    Six Sigma, Data Mining and Dead Customer Accounts

    In an interview with Quality Digest, Joseph M. Juran pointed out that quality needs to “scale up” if it is to remain a viable force in the next century. In other words, quality must spread beyond its traditional manufacturing base. A major opportunity to do just that now exists, as Six Sigma enjoys a resurgence […]

  • The Truth About DOE, Part 1

    The Truth About DOE, Part 1

    Design of experiments (DOE) and robust design of products are key parts of the Six Sigma process. To stay competitive, we need to offer great products to customers and we need to find and validate the optimum process settings to actually make the products. In short, we need a statistical model of our process. However, […]

  • The Truth About Transport Waste

    The Truth About Transport Waste

    We are all fortunate to have the accumulated knowledge of manufacturing industry titans readily available to help us improve processes and reduce costs. In the Lean context, Taiichi Ohno and Shigeo Shingo stand out. They taught us much about the process improvement mindset, visual control systems and the like. Both indicated the need to relentlessly […]

  • Thinking Outside the Box With PCA

    Thinking Outside the Box With PCA

    A common problem with SPC is that the world appears too complicated for a statistical approach to work. In complex electronics products, for example, circuit boards may have thousands of holes and microchips may have millions of transistors. Plotting control charts of each and every dimension is clearly not feasible. What can be done? To […]

  • Preventing Hospital Falls with Six Sigma

    Preventing Hospital Falls with Six Sigma

    Hospital processes produce many things. Most of them are desirable outcomes, such as healthy newborn babies, new hip joints, cancer-free patients and blood flowing freely through once-blocked coronary arteries. In other words, happy, healthy and satisfied patients. These results are why healthcare professionals chose their field. They generate revenue that patients are happy to pay […]

  • When in Doubt, Get the X-Chart Out!

    When in Doubt, Get the X-Chart Out!

    Phil looked at the data Joan had just handed him. Joan was a recent graduate of an SPC seminar the company had sponsored for administrative personnel and, since Phil had been the Quality Engineer who taught the classes, it was only natural that she would seek his help. She was trying her best to follow […]

  • Recognizing a Six Sigma Project Opportunity

    Recognizing a Six Sigma Project Opportunity

    Lean Six Sigma projects must help the organization achieve its goals. To accomplish this you must take action that guarantees that your project activities are directly linked to the goals specified by your leaders. Example of a CEO’s Vision Six Sigma begins with the vision of the senior leader and his or her team. The […]