Improve Phase – Introduction to Lean6Sigma Improve Phase

Lean Six Sigma – The Improve Phase

The fourth phase of DMAIC is the Improve Phase. The objective of the Improve phase is to apply the changes to the process being improved. Aiming to finding a solution, based on the uncovered problem, and where all the work you have done so far in your project can be implemented and start to show some success. It is here you develop, evaluate, select, and optimize potential solutions, and define what the process will look like after changes have been made to give you the right improvements to make to your processes.

The L6S DMAIC Improve Phase

4.3

Improve – Put changes into place that eliminate the root cause of problems

Leansixsigma Improve Phase Logo

The Improve Phase is where the team gets to solve the problem. They develop solutions, pilot the process changes, implement their ideas and collect data to confirm they made a measurable difference. This is where their hard work pays off.

  • Generate possible solutions
  • Select solutions
  • Implement solutions
  • Failure Mode and Effects Analysis
  • Stakeholder Analysis
  • Kaizen Event
  • Poka-Yoke
  • ... and much much more

Main Concepts:

  • Lateral thinking and brainstorming
  • Idea screening tools
  • Design of Experiments (DOE)
  • Management of Risk
  • Failure Modes and Effects Analysis (FMEA)
  • Design and Machine FMEA
  • Lean Concepts
  • SMED and Poka-Yoke
  • Jidoka, Heijunka, Kaizen and TMP

Here, we get to see where the actual changes to improve a process occur. 

 This course comprises the following modules:

  1. 1
    In this first module we investigate the technique of Lateral Thinking and its use in seeking solutions to intractable problems through unorthodox methods. I introduce the concept of random stimulus approaches in terms of words, association, and common images.
  2. 2
    In this second module you and I continue looking at Lateral Thinking and the various techniques that can be used for brainstorming including analogy, anti-solution, channeling, and brain writing.
  3. 3
    This is the first of two modules examining Idea Screening Tools and screening solutions. I take you through the sequence and the various filters used for the first pass on generated ideas. There are two techniques used here the Divided by Three (N/3) voting technique and the Pay Off matrix.
  4. 4
    This is the second part looking at Idea Screening Tools that I used in the second pass. The tools we will examine here are the Criteria-based Matrix and the Pugh Matrix.
  5. 5
    This is a very important module looking at the technique of called Design of Experiments (DOE). I discuss the eight-step approach to experimental design and introduce you to the concepts of levels, response, factors, and treatments used in experimental design. I describe the management of noise factors and define correlation.
  6. 6
    This is the first of two parts looking at the Management of Risk, and these two modules perform an introduction to the later topic of failure modes and effects analysis. I demonstrate the use of risk and risk management and take you through the first of several proactive risk management responses.
  7. 7
    This is the second part of the management of risk where I describe the use of Reactive Risk Management responses, the use of risk identification tools such as the risk breakdown structure and influence diagrams. I take you through the probability impact matrix and how it can be used to help manage risks.
  8. 8
    This is the first of three modules describing the use of a risk prevention tool called Failure Modes and Effects Analysis (FMEA). I take you through the definition and the process, introduce how risk reduction is carried out and calculated, and describe an FMEA template for capturing your failure modes and risks.
  9. 9
    In this, the second part of failure modes and effects analysis, you and I discuss the severity rating scale, the occurrence rating scale, the detection rating scale and I introduce use of the Risk Priority Number (RPN).
  10. 10
    This is the final of the three modules looking at failure modes and effects analysis, and I start with describing in detail the use of a typical FMEA Template. I take you through all 16 sections, describe what information they contain and how it is used. I described the calculations needed for the before state, and the after state once the recommended actions have been implemented.
  11. 11
    This final module concerning the use of FMEA, but with a difference, because here we look at what is called Design FMEA (DFMEA), and how it is used to identify the failure modes in product creation rather than process improvement. The final variant we look at is called machine FMEA (MFMEA), and I describe how this is applied.
  12. 12
    The remaining two modules are focused on looking at Lean Concepts and Tools. In this the first, I review the six tools that we are already familiar with from earlier DMAIC phases and introduce six new concepts and tools in the application of lean within the improve phase. I introduce the value stream map and remind you of the five key lean principles.
  13. 13
    In this module you and I examine the use of lean SMED and Poka-Yoke. For each of these tools I described that purpose, their application, and their benefits.
  14. 14
    In this, the final module within the DMAIC improve phase, you and I discuss Four Important Techniques. The first is Jidoka, the second is Heijunka, the third is Kaizen ending up with a technique called total productive maintenance (TPM)
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