Lean Six Sigma Bursts

In this episode, I share the audio from a panel discussion I was asked to participate on Wednesday this week. The discussion was focused on Lean Manufacturing, but we also discussed Six Sigma quite a bit. The event was hosted by the Texas Chapter of the Women in Manufacturing Association. They are the only national and global trade association dedicated to providing year-round support to women who have chosen a career in the manufacturing industry I'm sharing only the segments when I talked, but I encourage you to listen or watch the entire hour-long discussion. The other panelists were Crystal Davis, Dave Crysler, RaeJean Griffin, Sneha Kumari, and Troy Weier. I have a link to the association and the recording is in the links section below. Links Women in Manufacturing - Texas Chapter Women in Manufacturing Panel Discussion Video Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I provide some tips on how to close out a project or improvement effort, when the primary metric may longer than a year before you might be able to see tangible results. I also discuss other things you can do to prove in the short term that your improvements will be effective in the long run. Links Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I discuss a project I'm really excited about, the 2nd book release in the Lean Six Sigma for Good book series. This is the 2nd collection of real-life experiences and stories from Lean and Six Sigma practitioners who have spent time at the "gemba" with not-for-profit organizations. They have generously offered to write a chapter about lessons learned and tools they have applied. There are 8 chapters in total. Joe Wojniak and Lynn McCullough: Improving Thrift Shop Donations (interview with authors) - Proceeds donated to TRU Community Care Tim Turner: Helping Others By Following The Toyota Way (podcast interview with Tim) - Proceeds donated to Center for Quality People and Organizations (CQPO) Douglas Cooper: Lessons from Liberia – Standard Work as the Foundation for Lean Practices - Proceeds donated to Mercy Corps Anita Havemann: Reducing Time and Complexity in Nonprofit Accounting - Proceeds donated to Relay Resources Steve Bell: Simple Framework for Complex Problems - Proceeds donated to Lean4NGO.org lisabeth Swan: Leaning into the Mission of Childcare (podcast interview with Elisabeth) - Proceeds donated to Cape Cod Children’s Place Tracy O’Rourke: Increasing Meals Per Hour with Kitchens for Good (podcast interview with Tracy) - Proceeds donated to Kitchens for Good Joy E. Mason: Using Six Sigma to Address Racial Equity (podcast interview with Joy) - Proceeds donated to The Six Sigma Racial Equity Institute I think this is a great book to share with potential volunteers, or nonprofits or public service agencies wanting to learn more about how Lean or Six Sigma can be applied to their organizations. Links Learn more about Lean Six Sigma for Good: Lessons from the Gemba (Volume 2) Check out Lean Six Sigma for Good: Lessons from the Gemba (Volume 1) from back in 2019 Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I discuss two acronyms to help you remember ideas on how you can improve a process. ECRS stands for Eliminate, Combine, Rearrange, and Simplify. SPACER stands for Standardize, Parallel processing, Automate, Consolidate, Eliminate and Re-arrange. I also mention SCAMPER, which is similar to these, and stands for Substitute, Combine, Adapt, Modify, Purpose, Eliminate and Reverse. Links ECRS SPACER/SCAMPER Learn more about the Lean Six Sigma Virtual Coaching and Certification Program Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I discuss Action Priority (AP), a newer method for determining which risks from an FMEA should be addressed. Traditionally, the multiplication of Severity, Occurrence and Detection was used to calculate a Risk Priority Number (RPN). Any number over a certain RPN threshold required action to reduce the risk.  Action Priority gives three possible outcome for each risk identified: Low, Medium and High, which can make it easier to decide which RPN scores are more important than others. I also discuss the troubles I've had using a RPN threshold with FMEA teams, as they tend to score just below the threshold intentionally. Links Action Priority Lookup Tables (Excel) FMEA Tables with Scoring Matrices (Excel) Learn more about the Lean Six Sigma Virtual Coaching and Certification Program Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I explain a new virtual coaching program I'm launching in January of 2023.  If you or your team would be interested in completing some online Lean or Six Sigma training, completing a kaizen event or a Six Sigma project, and obtaining a certification, I have three approaches that might work for you at different price points: Do It With Me (Coaching) – We work closely with you to keep you on track with the training, and we help you with your Six Sigma project or Lean event over a 4-month period. Best combination of self-learning and mentoring. Do It Yourself (DIY) – You complete the training and project/event primarily by yourself, with a few hours of our support. Lowest cost option but requires self-discipline. Do It For Me (Consulting) – We take the lead on your Six Sigma project or Lean event, and coach/mentor you as needed, with focus on getting tangible results as quickly as possible. Most expensive but effective option. Links Learn more about the Lean Six Sigma Virtual Coaching and Certification Program Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I explain what a "single-stall production system" means, and why it is superior to the traditional single piece flow assembly line. Single-stall is a method of work where one highly skilled worker is trained to perform all steps of the process by themselves (often in one stall to reduce floor space), instead of handing off the work to multiple workers in an assembly line. It can take months or years to develop their skills so they can perform each step at high quality, but it can be the most efficient way to complete a process from beginning to completion. I share a link to an article I wrote below, and in the episode I explain the videos in the article that better explain the difference between single-stalls and assembly lines. Links Single-stall Production Systems Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I read off an article I just wrote, based on my 20+ years of teaching Lean concepts and principles. These are the topics that get the most attention, solicit the most questions, or are the most eye-opening for my students and clients.  I also announce the launch of a new Lean course I helped create, called Lean Fundamentals. You can access the FREE Lean Introduction course (first 5 modules) using coupon code "KICKSTARTLEAN-LSSE" Links LinkedIn article: Lean  Lean Introduction course (Free) Lean Fundamentals course ($249 USD) Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm Links from article 8 ways why batching is bad for your business Kanban Kaizen Andon 8 Types of Waste Reducing your time might seem like lean, but you can easily anger your customers Takt time Hoshin Kanri Learn how to plan a lean event What do I do with extra resources as a result of improvement without laying them off? Gemba

In this episode, I share the audio from a recent video I created. The short video highlights four different industry case studies applying Lean principles and concepts. The 4 organizations highlighted in the video: Omark Industries (Manufacturing) - Learn more at https://en.wikipedia.org/wiki/Lean_manufacturing Appvion (Manufacturing) - featured in the book Lean CEO at https://amzn.to/3QQjNiV City of Denver Colorado (Government) - Details available in this video at https://www.youtube.com/watch?v=puaT1KBY7Pg Virginia Mason Institute (Healthcare) - More details available at https://www.virginiamasoninstitute.org/resource/surgical-setup-reduction-improves-patient-outcomes/ Links Video: Lean Case Studies Across Different Industries - Manufacturing, Government and Healthcare Free Lean Introduction course - Use coupon code "KICKSTARTLEAN-LSSE" at checkout Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I share the audio from a recent video I created. The short video highlights four different examples of nonprofits and NGOs applying Lean principles and concepts to social challenges in the local community. I also announce our new Lean courses: Lean Introduction and Lean Fundamentals. The Lean Introduction course can be accessed for free using coupon code "KICKSTARTLEAN-LSSE" The 4 nonprofits highlighted in the video: St. Bernard Project (New Orleans, LA) Learn more at https://planet-lean.com/lean-construction-new-orleans-katrina/ Food Bank For New York City Learn more at https://www.youtube.com/watch?v=EedMmMedj3M Free Geek (Portland, OR) Learn more at http://www.sustainableengineer.org/free-geek-named-2021-excellence-in-sustainable-development-award-winner/ Project C.U.R.E. (Houston, TX) Learn more at https://www.youtube.com/watch?v=CIXDQAUSJD0 Links Video: Applying Lean Thinking and Process Improvement to Nonprofits and NGOs Case Studies LeanSixSigmaforGood.com - Case studies of nonprofits and governments applying Lean and Six Sigma for the greater good Free Lean Introduction course - Use coupon code "KICKSTARTLEAN-LSSE" at checkout Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I read off a recent article I wrote, breaking down the turnover data from the University of Iowa 2021 football season. I explain how I would evaluate their data using categorization and Pareto charts to identify more opportunities to create more turnovers against their opponents, or reduce the number of turnovers caused, which will increase their chance of winning games. Links Hawks Good at Turnovers, But Can Do Better Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I read off an article I wrote back a few years, about how the 5S workplace organization methods compare to the popular home organizing methods of Marie Kondo, developer of the KonMari method, which had become popular through her books and Netflix TV show. There are other links embedded within the article. Links Article: 5S and the KonMari method Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I discuss how I helped someone select a key metric for their Six Sigma project, based on the opportunity to measure and statistically validate the improvement. Links Lean Six Sigma Project Ideas Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I discuss a way to help identify a potential Lean Six Sigma project out of a larger improvement project taking place. Selecting a project is one of the hardest things to complete for those pursuing a Lean Six Sigma certification. Links Lean Six Sigma Project Ideas Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I discuss how I applied the Theory of Constraints (TOC) to come up with additional improvement ideas for a bottleneck process at a client I am working with. Before we invest in more people or equipment (throwing money at the problem), let's make sure we have extracted as much opportunity out of the existing process. Links What is Theory of Constraints? Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I discuss ways in which I've combined current event topics from the Iowa Hawkeyes sports teams with my data analysis and process improvement background. I explain a summary of 4 articles I have written, and invite you to read the ones that are of interest to you. Links True or False? Iowa Football Struggles in Games on the West Coast Will Jordan Bohannon Tie or Break the Big Ten 3-Point FG's Made Record? Did Iowa Women Suffer from Lack of Fouls in Loss to Creighton? Racial Differences in Football Player Retention at the University of Iowa Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I discuss a situation I encountered related to hiring new employees within a set period of time. Thinking about the problem in terms of takt time was helpful, so I thought I'd share that with everyone. If you don't know about takt time, it's a method to establish a pace or rhythm for how often a process needs to complete items. We take the time available divided by the number of items to determine a pace for the work. In this example, we use it to determine how often you need to hire people to meet your goal of 14 candidates. I also include adjustments to the demand to account for losses through the process, such as no-shows, not being qualified, and not accepting the job. Links Takt Time on LeanSixSigmaDefinition.com Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I share the 7th and final module of the free "Lean at home" course, giving you a full example of a home improvement project. Hopefully you will be inspired to make similar improvements to your own personal life. If you complete a similar project to this at home, you can submit the project workbook to me for review, and obtain a "Lean at Home" certification. If you want to watch all the videos of this course or access the workbook, you can access the entire free course, called "Home Efficiency Using Japanese Lean Productivity Techniques" at https://business-performance-improvement.thinkific.com/courses/home-efficiency-using-japanese-lean-productivity-techniques Links Free Lean at Home Course Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I share the 6th module of the free "Lean at home" course, giving you ideas about how to error proof your home from mistakes, and documenting the new process using checklists and standard operating procedures or SOPs. At the end of the course, you will have the option to implement a project and get a "Lean at Home" certification. Over the next few weeks, I will upload other modules from the course. But you don't have to wait. You can access the entire free course, called "Home Efficiency Using Japanese Lean Productivity Techniques" at https://business-performance-improvement.thinkific.com/courses/home-efficiency-using-japanese-lean-productivity-techniques Links Free Lean at Home Course Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I share the 5th module of the free "Lean at home" course, helping you understand how to organize your home using the 5s method. I also go through an example of organizing my mom's sewing room. At the end of the course, you will have the option to implement a project and get a "Lean at Home" certification. Over the next few weeks, I will upload other modules from the course. But you don't have to wait. You can access the entire free course, called "Home Efficiency Using Japanese Lean Productivity Techniques" at https://business-performance-improvement.thinkific.com/courses/home-efficiency-using-japanese-lean-productivity-techniques Links Free Lean at Home Course Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I share the 4th module of the free "Lean at home" course, helping you learn about the 8 forms of waste, and how you can spot these wastes in your home process. At the end of the course, you will have the option to implement a project and get a "Lean at Home" certification. Over the next few weeks, I will upload other modules from the course. But you don't have to wait. You can access the entire free course, called "Home Efficiency Using Japanese Lean Productivity Techniques" at https://business-performance-improvement.thinkific.com/courses/home-efficiency-using-japanese-lean-productivity-techniques Links Free Lean at Home Course Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I share the 3rd module of the free "Lean at home" course, giving you ideas about what data to collect, and how to better understand your home processes by creating a process map or spaghetti diagram.  At the end of the course, you will have the option to implement a project and get a "Lean at Home" certification. Over the next few weeks, I will upload other modules from the course. But you don't have to wait. You can access the entire free course, called "Home Efficiency Using Japanese Lean Productivity Techniques" at https://business-performance-improvement.thinkific.com/courses/home-efficiency-using-japanese-lean-productivity-techniques Links Free Lean at Home Course Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I share the 2nd module of the free "Lean at home" course, giving you ideas about which process at home you could select for your improvement project. At the end of the course, you will have the option to implement a project and get a "Lean at Home" certification. Over the next few weeks, I will upload other modules from the course. But you don't have to wait. You can access the entire free course, called "Home Efficiency Using Japanese Lean Productivity Techniques" at https://business-performance-improvement.thinkific.com/courses/home-efficiency-using-japanese-lean-productivity-techniques Links Free Lean at Home Course Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I share the introductory module of the free "Lean at home" course, explaining why I made this course, and why it's a great starting point for anyone interested in learning and practicing Lean and process improvement methods. Over the next few weeks, I will upload other modules from the course. But you don't have to wait. You can access the entire free course, called "Home Efficiency Using Japanese Lean Productivity Techniques" at https://business-performance-improvement.thinkific.com/courses/home-efficiency-using-japanese-lean-productivity-techniques Links Free Lean at Home Course Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I talk about a useful matrix that helps you identify cross-training and skill development opportunities with your team or in your organization. It's called a cross-training matrix, or a skills matrix. Each skill is listed on one side, and each team member is listed on the other side of the matrix. For each combination of skill and person, you determine how much experience they have by filling in a circle (called a harvey ball). I'm including a link to more details, and an Excel template you can download and use for free. Links Cross-Training Matrix on LeanSixSigmaDefinition.com Free Excel Template for Cross-Training Matrix Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I rant about the lack of effort some organizations put into their process improvement programs, and then are surprised that it didn't work, and want to blame the tools and methods, not their strategy for deploying it. Links Need help in your organization? Let's talk! Schedule a free support call BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I read the book review I wrote about the book, "The Lean Dentist." It is based on the lean journey of Dr. Sami Bahri, DDS, who is an experienced dentist in Jacksonville, Florida. He has been an avid learner looking for ways to improve his dental clinic, and shares his transition journey to a "one-patient flow." You might also find the book in its original title, "Follow The Learner." Links Book review: The Lean Dentist (origin blog of this podcast) Buy "The Lean Dentist" "Go See, Ask Why, Show Respect" luggage tags Taiichi Ohno - The Toyota Production System (Audible) BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I talk about the importance of collecting data in the very beginning before you start an improvement project or initiative. The example I use is measuring how much sleep we get a night, and collecting data to see if the current performance is below a target or goal you have. It might not be as bad as you think, or maybe it's worse than you thought. Collect the data first. Links Six Sigma Analysis: Is The COVID-19 Quarantine Helping My Sleep? BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I talk about some other ways to identify waste and opportunity in your process and workday, specifically the tasks that you are not doing, but should be. This proactive work doesn't happen, so you often don't realize that you didn't get around to it. It later shows up as actual waste when something goes wrong or there are problems, but it's too late. Start to notice these proactive activities that you aren't doing as opportunities for improvement. Links Honda Statistical Process Control video BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

In this episode, I go on a little rant about books, and how I estimate there are a lot of unread books in people's homes and offices. I'm considering a challenge to get people to read some of their unread books, or get rid of them and free up space in your home. Would you be interested in this challenge? Links Book: Joy at Work by Marie Kondo and Scott Sonenshein Article: 5S and the KonMari method Training: FREE "Lean at Home" course (Home Efficiency Using Japanese Lean Productivity Techniques) BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

I was asked a question about how to get started applying Lean and Six Sigma to a non-manufacturing business. I thought about some key questions I would want to ask, and sent them a response. I thought they were good questions, so I wanted to share them on the podcast.  Links BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

During a recent coaching call with a client, we discussed applicability of statistical process control (SPC) and control charts (also called process behavior charts) in their operations. I sent them a link to the Honda SPC video (older but highly recommended) and I share the comments I made to elaborate on what they saw.  Links Honda Statistical Process Control video BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

After conducting a Lean 101 webinar for Lean Portland, we had some excellent questions from the attendees, so I thought I share my answers. The first question was looking for advice on how management can support their employees instead of just giving them their idea on what the answers are. The second question asked about how to deal with managers who think that no complaints means no problems. You can watch the full Lean 101 webinar in the links below. Links Lean 101 Webinar BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

After conducting a Lean 101 webinar for Lean Portland, we had some excellent questions from the attendees, so I thought I share my answers. The first question was looking for advice on how to make their forms easier and more streamlined for their customers. The second question asked about how to create psychological safety and build trust in their organization when top management doesn't seem to be driving it. You can watch the Lean 101 webinar in the links below. Links Lean 101 Webinar BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

After conducting a Lean 101 webinar for Lean Portland, we had some excellent questions from the attendees, so I thought I share my answers. The first question was looking for more explanation about batching vs one piece flow. The second question asked about classical vs lean management methods. You can watch the Lean 101 webinar in the links below. Links Lean 101 Webinar BIZ-PI.com Creative Safety Supply (enter code "BPI" to save 10%) Have a question? Submit a voice message at Anchor.fm

Project charters for improvement projects do not have solutions listed. Instead, they should explain the problem, the management support for this project, the key team members, the scope, the timeline and key metrics of success. They should not have the proposed solution, as we shouldn't have that figured out yet. We still need to follow the problem solving approach. I explain my thoughts on this in more depth. Links BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

Developed by Genichi Taguchi, the Taguchi Loss Function is a graphical representation of how an increase in variation away from the target value (even within specification limits( leads to an exponential increase in customer dissatisfaction. This is different than the traditional approach of viewing results within the specification limits as good, and results outside of the specification limits as bad. Links Taguchi Loss Function Video of Ford Transmission Study: https://www.youtube.com/watch?v=uAfUOfSY-S0 BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

When describing the methodology of a kaizen or kaikaku event, I often break it up into two main types: Working session - traditional approach where 80% of the work is implemented during the 2-5 day event Planning session - process mapping approach where the team generates a 90-day action plan during the 2-5 day event I explain the differences and when to use each type, along with describing how projects and point kaizen (or kaizen blitz/burst activities) fit within these activities. Links What is Kaikaku? Video of Kaizen Planning Event: https://www.youtube.com/watch?v=YYsn0X0EVRI Video of Kaizen Working Event (within a larger 8-week project): https://www.youtube.com/watch?v=EedMmMedj3M Video of Kaizen Blitz or Point Kaizen: https://www.youtube.com/watch?v=QA1ddcXfqM0 BIZ-PI.com Creative Safety Supply Have a question? Submit a voice message at Anchor.fm

A common question I hear is "what if my company doesn't support process improvement?" I share 4 main approaches you can take to deal with this situation, instead of feeling frustrated by it. Links LeanSixSigmaHomes.com BIZ-PI.com Creative Safety Supply Have a question? Submit a voice message at Anchor.fm

I share my experience getting my first COVID-19 vaccine shot, and how I analyzed that process from a lean perspective. I found that there was only one second of value, compared to a process that took me over an hour to complete. On a related note, I also have some links to lean applied during the pandemic on my website (see links below). Links Applying Lean Methods to Mitigate COVID-19 at Work BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

I was recently asked about the difference between PDCA and PDSA. I had heard some new information from another podcast, and dug into one of the references to learn more about it. In this episode, I read through a paper from Ronald Moen that provides a good historical perspective. Note: I mispronounced Charlie Protzman's name in the audio. Apologies! Links Foundation and History of the PDSA Cycle - Ronald Moen  Podcast Interview with Charlie Protzman and Patrick Adams BIZ-PI.com Creative Safety Supply Have a question? Submit a voice message at Anchor.fm

A recent Value Stream Mapping event was held virtually, and we received some positive feedback from the event attendees. I wanted to share some of the comments to show how process improvement helps much more than just faster processes with less quality issues. It helps engage employees in the future direction of the organization, builds teamwork across departments, and creates a safe space for discussing problems and challenges. Please contact me if you'd like help with facilitating your own lean events, so I can better understand how to assist you in this important tool of process improvement. Links Value Stream Mapping Training (YouTube) Kaizen Event Training (YouTube) BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

Does your organization use a structured problem solving process, like DMAIC, 8D, or PDSA? If no, why not? I share my views on what challenges are created when you don't have structure to your problem solving approach. Links BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

Are you trying to decide how to select the best projects to work on, but have many stakeholders and customer needs to consider, and too many project ideas? Check out the Project Prioritization Matrix to help you objectively evaluate these projects and select the ones that meet the most important criteria. I pulled the audio from the training video for you to listen to in this podcast. There is also a link to the video if you had trouble following along, and I provide a link to the template you can download.  Links Video: What is a Project Prioritization Matrix? Selecting the Best Projects with Many Stakeholder Criteria Template: Project Prioritization Matrix (XLSX) BIZ-PI.com LeanSixSigmaDefinition.com Have a question? Submit a voice message at Anchor.fm

I received a question today that I thought would be helpful to everyone: “Imagine you are getting ready to kick-off the value stream workshop and you start to receive emails from a bunch of different people in the organization asking to attend. What would be your response?” I answered the question in an article on my website, but I wanted to read my response for this podcast. Links Article: How to decide on the right number of people for your lean event? BIZ-PI.com LeanSixSigmaDefinition.com Creative Safety Supply Have a question? Submit a voice message at Anchor.fm

When making improvements to a process, cost savings and avoidance is a common outcome that is estimated and reported. A common error is to combine the data together into one overall number, but they should be separated into three distinct buckets of money: Income Statement, Cash Flow and Growth.  Links Article: Client saved $800,000 in 3 Days E2: What is the difference between hard and soft financial savings? BIZ-PI.com LeanSixSigmaDefinition.com Creative Safety Supply

One of the most impactful quality initiatives I was involved with was the creation and deployment of the Cost of Nonconformance (CoNC) report. It was a method to assign a dollar amount to quality problems in order to bring attention to management in the language they most often respond to, money! It could also be applied more broadly beyond just quality issues to any type of waste to increase visibility for your Lean or Six Sigma initiative. Check out our Cost of Poor Quality course at https://www.biz-pi.com/product/cost-of-poor-quality-copq-course/ Links BIZ-PI.com Cost of Poor Quality Course LeanSixSigmaDefinition.com Creative Safety Supply

In process improvement, there is a strong focus of data. But in order to analyze data for an improvement project, you need to know what type of data you have or need, so you can perform the correct analysis. I share the different types of data you may encounter for your project. Links BIZ-PI.com LeanSixSigmaDefinition.com

I saw a recent question in a forum, asking about the origin of the sample size of 30 data points. I decided to read you the response I gave, and make it a new blog post on my website.  Links Article: Why do we need 30 data samples? BIZ-PI.com LeanSixSigmaDefinition.com

I share an article I wrote back in Dec 2013 about reducing or eliminating test or inspection steps using Six Sigma analysis methods of capability and stability, along with risk mitigation tools like FMEA and error proofing. Links Article: Top 3 things to validate before removing test or inspection steps Article: Which Should You Use Cpk or Ppk? BIZ-PI.com LeanSixSigmaDefinition.com

I share an interview I did with Mark Graban about why I created this podcast. He included me in a new networking group called Lean Communicators. We are a group of podcasters that talk about Lean, and we meet about once a month to discuss best practices and learn from each other. Check out the website of all the contributors at LeanCommunicators.com, where you can subscribe to an email list of new episodes from all contributors, or subscribe to individual podcasts. You can also follow us on LinkedIn using #LeanCommunicators. Mark also appeared in Episode 11 of this podcast, so you can hear his questions and my responses. Links LeanCommunicators.com LinkedIn #LeanCommunicators Lean Blog Podcast #394 with Mark Graban - Interviews with Lean Communicators network Lean Six Sigma Bursts - Episode 11 with Mark Graban BIZ-PI.com LeanSixSigmaDefinition.com

Most people calculate the average when summarizing data, but what about the median? The median is not as sensitive to outliers and skewed data, and can be a better indicator of the typical or most common outcome in your data. Links Wikipedia: Median BIZ-PI.com LeanSixSigmaDefinition.com

Do you see problems recur later after all the attention has gone away? That could be the Hawthorne Effect at work, which can create confusion on whether your improvements are actually working. Links Wikipedia: Hawthorne Effect BIZ-PI.com LeanSixSigmaDefinition.com

When I facilitate mapping events, after completing the current state map and before we create the future state map, I like to first walk the team through an ideal state discussion. I categorized these concepts and share the list with you in this podcast. Links Why I like using the Ideal State Mapping approach BIZ-PI.com LeanSixSigmaDefinition.com

Ground rules are an important element of running a successful process improvement event (called Kaizen Blitz or Kaikaku events). In this podcast, I share a compiled list of rules that you can use as a starting point for your next improvement workshop. Links List of Typical Lean Kaizen Event Ground Rules BIZ-PI.com LeanSixSigmaDefinition.com

During some recent travel, my wife and I ended up watching multiple episodes of "Bar Rescue."  I've watched the show for many years, so I re-watched it with a new lens, now that I'm consulting on my own.  As I thought about my approach to consulting, how would I help these bars and restaurants make dramatic improvements? Listen for my comparison of how I would prefer to help these bars versus the approach used by host Jon Taffer. Links JonTaffer.com Bar Rescue Show BIZ-PI.com LeanSixSigmaDefinition.com

I discuss the Lean approach to writing a book, which is how I published my first 2.5 books. LeanPub.com allows you to write and publish your book for free and release similar to software, instead of one large batch like in traditional book publishing.  Links LeanPub.com Lean Six Sigma for Good: How improvement experts can help people in need, and help improve the environment Lean Six Sigma for Good: Lessons from the Gemba (Volume 1) Lean Six Sigma for Good: Lessons from the Gemba (Volume 2) BIZ-PI.com LeanSixSigmaDefinition.com

I discuss the internal Lean Six Sigma certification program I helped develop and implement at Rockwell Collins (now Collins Aerospace), and why I think it's a good model for other organizations to consider if you want to offer certifications. Links BIZ-PI.com LeanSixSigmaDefinition.com

If you've struggled to decide what improvement project to work on at work or for a certification project, check out this list of project or event ideas that you could consider for your industry. I have examples from the following categories: Personal Life, Finance and Accounting, Human Resources, Sales, Shipping/Receiving and Warehouse, Information Technology (IT), Product/Service Design, Call Center, Healthcare, Manufacturing, Sports, Grocery/Supermarket, Nonprofits, Environment, Corporate Responsibility, Diversity/Equity and Inclusion, and Education. This is a longer podcast than usual, so I apologize but hope you found it useful! Links Lean and Six Sigma Project Ideas Check out our FREE “Lean at Home” online course for ways to improve your personal life! BIZ-PI.com LeanSixSigmaDefinition.com

I try to simplify some confusion about the 7 types of waste (or are there 14 types?), the 3 M's, and explain simpler ways to think about opportunities in a process. Links Article: From 7 Wastes to 3 – The Yamada Method Acronyms for remembering the wastes BIZ-PI.com LeanSixSigmaDefinition.com

I finished writing an article about two sustainability certification programs that require continuous improvement, but don't give guidance on how to do that. I explain why I think Lean is the best method to adopt for these mission-driven organizations. I also share examples below in the links about why I think Toyota is a leader in community engagement and environmental causes, not just financial performance. Links Article: Continuous Improvement key to B Corps, Fair Trade and other mission-driven organizations BIZ-PI.com LeanSixSigmaDefinition.com Toyota Toyota Kentucky facility reflects parent company’s commitment to the environment Toyota and the Earth Charter Toyota Production System Support Center (TSSC) - Donates time to nonprofits and government agencies

I had a call this week helping out with a Black Belt project, and I was reminded about the Standardize-Do-Check-Act model that should be implemented first, before trying to make improvements to a process using the PDCA model (Plan-Do-Check-Act) Links BIZ-PI.com LeanSixSigmaDefinition.com Kaizen - The Key to Japan's Competitive Success by Masaaki Imai Photo from Masaaki Imai's "Kaizen" book about SDCA and PDCA

I received two questions from Mark Graban about my first episode. He is a well-known Lean consultant with expertise in the healthcare industry, and has authored multiple books, including Lean Hospitals and Healthcare Kaizen and Measures of Success. He is also the host of multiple podcasts, including Lean Blog and My Favorite Mistake. Learn more about him at MarkGraban.com Links BIZ-PI.com LeanSixSigmaDefinition.com Episode 1: Why are Six Sigma Black Belts paid so much? MarkGraban.com

During Lean and Six Sigma classes, I meet a lot of people who are good problem solvers already, and they mention that the topics are similar to how they approach problems. Here are some of my observations about my interactions with them, and what takeaways I gathered. Links BIZ-PI.com LeanSixSigmaDefinition.com

I share exciting news that we have digital access to Norman Bodek's past PRODUCTIVITY newsletters from 1980-1993. He lived in Vancouver, Washington (near Portland), but was moving to Japan permanently, and we have scanned in the documents for you to search, download and review. Links BIZ-PI.com LeanSixSigmaDefinition.com PRODUCTIVITY newsletters and interviews with Norman Bodek

I discuss the simple visual management templates called SQDC (also called QDIP). These visuals help simplify the daily management for a process area, to quickly bring attention to areas that need help. A video of the discussion is available on the product page in the link below Links BIZ-PI.com LeanSixSigmaDefinition.com Watch a video or download the SQDC templates

I discuss the Lean at Home contest being run by Lean Portland. We are giving away $200 in prizes to those who submit an improvement project at home that was completed in the last 6 months. We also have a free online course you can take if you need some help! Links BIZ-PI.com LeanSixSigmaDefinition.com "Lean at Home" contest "Lean at Home" - Free online course

I explain what Pareto charts are, and why they should be used more often than they are. I also summarize an older article I wrote about changing the way to display these charts. Links BIZ-PI.com LeanSixSigmaDefinition.com (Pareto) New spin (literally) on an old quality tool

I explain how and when hypothesis tests can be used, based on a recent article I wrote, which looked at the racial inequities brought up by football players at the University of Iowa and the data that can support these claims. Links BIZ-PI.com LeanSixSigmaDefinition.com Affordable Green Belt Training Racial Differences in Football Player Retention at the University of Iowa

I created a video that accompanies this quick explanation of DMAIC, which stands for Define, Measure, Analyze, Improve and Control. DMAIC is the core structure used in Six Sigma projects Links BIZ-PI.com LeanSixSigmaDefinition.com Video of DMAIC Overview

In this episode, I discuss the Influencer behavior change model, and how it applies to getting people to wear their masks to prevent the spread of COVID-19 Links BIZ-PI.com LeanSixSigmaDefinition.com Article: How Behavior Change Can Influence Wearing of Masks

In this episode, I answer a question I often receive about how to categorize financial cost savings from improvement, either hard or soft, and what is the difference? Links BIZ-PI.com LeanSixSigmaDefinition.com

In this first episode, I answer a question I received about salaries for Six Sigma Black Belts, and why I think they make good money. Links BIZ-PI.com LeanSixSigmaDefinition.com