To identify sources of variability using historical or current data:
Provides objective solutions to questions which are traditionally answered subjectively
Works for differences in means, or Variances (Standard Deviations), or proportions
‘Poka Yoke’ is a technique for eliminating errors, used by Black Belts for solution generation and preparing implementation;
such that it is …Impossible to make mistakes, …Inexpensive, …Very effective, …Based on simplicity and ingenuity.
“poka” means an inadvertent mistake, “yoke” means to prevent, it originates by mr. Shigeo Shingo (1909-1990) in Japan.
Error proofing is a very simple technique.
You should keep it in mind at all times, but particularly when you are designing the solution or the improvement
Ideally you should prevent all possibility of the problem occurring, elmination;
If you can’t do this, you should then try to
…in that order!
To save Lead time (calendar time) we can, through Lean Six Sigma or Lean engineering the process steps that are currently being completed in series.
Another possibility is to take out some process steps from the series and do them in parallel to other process steps.
This is often called concurrent engineering; the idea being that you can design the different parts of a product at the same time. Unless concurrent or parallel processing is carefully planned and coordinated, it results in chaos.
Two things are required for Parallel processing:
IN-, DURING, AFTER- process improvements, productivity can be measured, look for the metric of efficiency with which resources such as labour or capital are employed in the production process. There are two widely used productivity measures; labour productivity and multifactor productivity. Lean Six Sigma programmes will support on this.
Black Belt training? Why is it different to previous improvement initiatives?
With in-company training one actually aligns process improvement to customer requirements and business objectives. It can be applied to service and business processes, not only for production processes.
With a Black Belt program in-house one establishes a standard language and problem solving methodology across different business functions.
The improvement goals are all bottom line focused and will provide the company a significant return on investment, i.e. improvement of On Time Delivery, structural financial benefits through efficiency and cost savings, increased customer confidence.
Black Belt project manager must ensure team work, this includes the coaching and training of Green and Yellow Belts. A proper change management project should not take longer than 6 – 8 months. Black Belts are trained to make use of DMAIC.
An organisation can relatively easy grow improvement competences and culture on a massive scale through in-house training, the purpose of the qualification and coaching of Black Belts is to engage all of the people in this drive for continual process improvement.
Deploying one unified methodology, language and tool kit will support companies to promote integration and common ways of working with respect to performance improvement and to progressively reduce its dependence on external consultants.