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Plackett-Burman experimental design is used to identify the most important factors early in the experimentation phase when complete knowledge about the system is usually unavailable. Developed in 1946 by statisticians Robin L. Plackett and J.P. Burman, it is an efficient screening method to identify the active factors using as few experimental runs as […]

The two-sample t-test is one of the most commonly used hypothesis tests in Six Sigma work. It is applied to compare the average difference between two groups. You use it to determine if the difference is significant or if it is due instead to random chance. It helps to answer questions like whether […]

Do you know how to account for the margin of error in your customer surveys? A survey is a valuable assessment tool in which a sample and information relate to a larger population. Surveying is like tasting a soup, a few spoonfuls tell what the whole pot tastes like. An Example of Margin […]

How do you implement the Six Sigma methodology? Consider the 5W1H approach when implementing it for your organization. 5W1H (who, what, where, when, why, how) is a method of asking questions about a process or a problem taken up for improvement. Four of the W’s (who, what, where, when) and the one H […]

Lead time vs. cycle time, which do you choose? Improving your processes is a nuanced and complicated thing. Understanding the difference between the various measurements of time can only benefit your workflow. So, let’s dive into what this means and how it applies to your production. What is Lead Time? Lead time is […]

What is poka-yoke? Have you ever accidentally microwaved your face? No? You’ve never opened the microwave door while it was cooking and accidentally exposed your face to microwave energy? I know that you haven’t because whenever you open the door, the microwave stops running. There is a switch that triggers when the door […]

The upper specification limit represents the highest limit that a measurement or reading can reach and still be acceptable to the customer. There are several benefits of monitoring USL and determining if a process can satisfy customer requirements.

Why is 6 sigma 3.4 ppm, not 2 ppb? The calculation of process sigma after a process improvement project should be reported as short-term sigma.

Do you hear voices? In a business context, that’s normal. Let’s listen in to the voice of the business and hear what it has to say.

The word Normal generally has a positive connotation. When applied to statistics, the term Normal Distribution has essentially the same effect. Let’s see why. 

Out-of-control Action Plans (OCAPS) are a piece of the Lean Six Sigma methodology that is often overlooked. Though they have been phased out in some organizations, it is important to understand their purpose and how they can help a company improve its processes.

Non-value-added is the work your customer is not paying you to perform.

Cp is one of the metrics calculated for determining whether your process is capable of meeting customer specifications or requirements. It is useful in comparing different functions and their ability to meet their unique specifications.

Do you feel that implementing change in your organization is going too slowly? So did Jack Welch of GE, which is why GE developed the Change Acceleration Process (CAP). Let’s explore how the concepts of CAP might help your organization.

Cycle time vs. throughput time, do you know the difference? Typically, when we look at the steps of our workflow, you’ll want metrics to gauge effectiveness and efficiency. Depending on the scenario, you’ll want to use one of these two metrics while looking at the work time needed to complete a deliverable. What […]

As competitive and market pressures increase, having a clear understanding of product reliability, service life, and expected failure rate is crucial. We explore how by utilising B10 life, we can optimise our product development and satisfy our customer requirements.

Statistics is a branch of math that involves the collection, description, analysis, and inference of conclusions from quantitative data. But what is a statistic? Let’s find out. The word statistic is a word with numerous possible definitions. In its simplest form, a statistic can be defined as a descriptor of a set of […]

Does your data from yesterday represent the current state of your process better than that from a month ago? How can you place more emphasis on it yet still make use of older data? That’s what the Exponentially Weighted Moving Average does. 

Do you know the difference between tangible vs. intangible benefits? Measuring the results of your company’s output can be of vital importance. Understanding how these two measurements line up and differ from one another can help refine productivity. Additionally, failing to pay attention to these measurements could have serious ramifications. What Are Tangible […]

House of Quality? No, this is often referred to as a House of Pain because of the effort needed to complete one. Let’s see if we are just being overly pessimistic. 

Six Sigma at many organizations simply means a measure of quality that strives for near perfection. Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process — from manufacturing to transactional and from product to service.

Use this table to go between and convert Sigma to DPMO to Yield to Cpk.

Null hypothesis vs. hypothesis, which is the right choice? When you get into the different methods of analyzing data, there is no shortage of tools at your disposal. Understanding the difference between a null hypothesis and a hypothesis can make or break your testing and analysis stages. Let’s dive into both of these […]

Lean Six Sigma professionals, much like every other professional, love to talk in acronyms. The acronym of the day is DPMO. Let’s check out what it means.

Defects per opportunity, or DPO, refers to the number of defects that occur in relation to a given number of opportunities for which an error could occur. Let’s consider some of the benefits of measuring and monitoring DPO.

Flowchart vs. process map, what do you choose to use? When it comes to mapping out a project, you’ve got several choices on how to visualize them. If you’ve had trouble deciding on a format for your visualization, then read on. Today’s guide is meant to cast more light on these individual tools […]

What is rolled throughput yield? Your company has just announced that its product line has a 100% total throughput rate, touting it as a great win for everyone. However, from your perspective, you see massive amounts of rework being performed, disrupting the production lines, costing additional money, and impacting on-time delivery. If only […]

An organization may hear many voices (Customer, Business, Employee, and Process). It is the voice of the customer (VOC) that is the driving voice. Additionally, it is what should be important to the organization and what the organization should focus on. The satisfaction of the VOC needs to be balanced against the Voice […]

ZARA changes its clothing designs every two weeks, offering 11,000 distinct garments annually. In comparison, competitors change their designs every three or four months and produce 3-4,000 distinct pieces. This is fast fashion: the business model of replicating high-fashion, luxury-brand pieces quickly and cheaply, making them available to customers while the trend and […]

Is your data normal? If not, will that be a problem? It might be, since data normality can be important when using certain statistical tools to make your business decisions. 

Capability Indices How do you calculate capability indices? Capability analysis is an essential tool for statistical process control (SPC) and process improvement, applicable to a variety of environments from hospitals and labs to assembly and manufacturing. How to Calculate Capability Indices The formula for calculating a Cpk index is easily found: USL, upper […]

The Harada method helps individuals achieve self-reliance which in turn facilitates a company’s process improvement journey. Part One provides an overview of the method and its genesis. Subsequently, part Two presents five templates to use to plan a goal, measure the goal’s progress, and assess success. An example helps illustrate their practical use. […]

Process Work How do you measure process work? When first introduced in the 19th and early 20th centuries, time and motion studies established rules of motion that guaranteed optimal performance during a given period and reduced the number of movements needed to get work accomplished. Over the years, time and motion studies have […]

Quality is one of those words and concepts that have many meanings. Let’s review the concept and discuss the different definitions associated with the term. It refers to the degree of excellence or superiority of something, often concerning its intended purpose or function. Further, it is a measure of how well something meets […]

This article will introduce you to control limits. You will learn about the role of control limits, how they were designed, and the role they play in process improvement.

Six Sigma is a data-driven approach to quality, aimed at reducing variation and the associated defects, wastes, and risks in any process. This article explores the basics of Six Sigma process quality – definition and measurement. Defining Standard Deviation In a set of data, mean (μ) and standard deviation (σ) are defined as: […]

How do you convert DPMO to Sigma Level? There are several metrics you can use to measure how well your process is performing. Let’s look at three of them and discuss how to calculate them and how they relate. The three are DPMO, Sigma Level, and Cpk. Convert DPMO/Sigma to Cpk  Before discussing […]

In today’s fast-paced, technology-driven world, fostering a culture of innovation and agility is essential for startups that want to stay competitive. Startups thrive on innovative ideas, quick pivots, and the ability to adapt to change. This 2014 article raised awareness of Lean Startups. But creating an environment where continuous improvement and creativity flourish […]

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 […]