Even Einstein had thoughts about Lean Six Sigma (#6)

How do you improve a process? Just ask Einstein.

We can’t exactly ask the genius physicist for advice on how to improve our processes, but we can take his theories and apply them to our Lean Six Sigma methodology.  The three main solutions to improving a process would be to Simplify, Innovate, or Automate.

Six Sigma Development Solutions, Inc. teaches the “Hierarchy of Improvements” to our students. This Hierarchy follows the process to Simplify, Innovate, then Automate. To help them understand, we tell a story that defines exactly how you should improve a process.

To begin, we show a video of an extremely complex process Western Union uses to certify new vendors. A process that totals 19 days! When watching this video, we request our students write down the areas of waste that they view in the process that they believe adds unnecessary time.

At the end of the video, we talk about their discoveries; talking about the waste they saw in the process. We then ask our students, “how do we eliminate 75% or more of the waste in this process?”

Most of the time, the answer is to “Automate,” which is not surprising considering the technological age that we currently reside it. To best answer that question, we like to respond with an example.

If we draw the Western Union process by writing each step on a sticky-note, then sticking them up on the wall in order, our process map would span several walls. The audience tends to respond by nodding their agreement. We give our students three options to choose from; these options reflect the “Hierarchy of Improvements” we discussed earlier.

Option 1: Add sticky notes to our process map

Option 2: Remove sticky notes and replace them with other sticky notes

Option 3: Remove sticky notes from our process map

Typically the option chosen is option #3.

Then we discuss what option 1 and option 2 look like in the real world.

Option 1 (Add sticky notes to our process map) looks like checklists, multiple inspections and sign offs. This option is one of the main causes for complexity that builds up within a process over time.

Option 2 (Remove sticky notes and replace them with other sticky notes) is our “knee jerk” reaction to improving a process. This relates to automate in the sense that we pull sticky notes off the wall (manual steps) and replace them with other sticky notes (SAP, ERP’s, MRP’s, etc.). Here is where Einstein comes into play. When we talk about Option 2, we like to refer to a famous quote from Einstein; “You cannot solve problems with the same thinking that got you into them.” This leads into another quote that states “What is the definition of insanity? Doing the same thing over and over, expecting different results.” Instead of improving our process, this just exchanges complex manual processes for complex digital processes. Though the process may look different, it does not resolve the complexity that affects the result.

Option 3 (remove sticky notes from our process map) is the most cost-effective solution. This option relates to “Simplify” in our “Hierarchy of Improvements” by separating non-value adding steps from value-adding steps. Once the steps are separated into these two groups, we prioritize the wasteful (non-value adding) steps by level of difficulty to later reduce or eliminate. By reducing or eliminating steps, we increase capacity, lower operating costs, and decrease the chance for error.
To conclude our discussion, we watch another YouTube video from Western union that shows the improvement to their certification process. Remember, the goal was to reduce the process time by 75%.

What an incredible improvement! Transforming their lead time from 19 days to 22 minutes came from understanding where the waste really was and directing their improvement efforts towards that waste. By following the “Hierarchy of Improvements” and Simplifying instead of Automating, they improved their process by leaps and bounds.
  
About Six Sigma Development Solutions, Inc.

We are Certified as an Accredited Training Organization with the International Association of Six Sigma Certification (IASSC)

“The IASSC Accredited Training Organization (ATO) designation validates Six Sigma Development Solutions, Inc. has demonstrated adequate management systems, courseware with a high degree of correlation to the subject matter contained in the IASSC Bodies of Knowledge, delivery schema consistent with such content and highly qualified instructors.”

We Provide Public Lean Six Sigma Lean Six Sigma Green Belt and Lean Six Sigma Black Belt Certification Training Courses in 34 Cities across the globe.


We Provide Onsite Lean Six Sigma Certification Training. Some of the training's we provide are: Lean Six Sigma Black Belt, Lean Six Sigma Green Belt, Lean Six Sigma Yellow Belt, Lean Six Sigma Champions Training and Lean Certifications for Healthcare, Finance, I.T, Manufacturing, Processing, Logistics, Retail Sales and Government.

SSDSI will come to your site to train for your choice of the Lean Six Sigma Certification Levels. Onsite training is more cost effective than open enrollment training when training larger groups of team members.

Benefits of Onsite Training:

The Training is focused on Your Opportunities

SSDSI uses your opportunities in class (vs. generic examples)

You will get the experience of a seasoned Lean and Six Sigma Master Black Belt who will help mentor you while completing your Lean and Six Sigma Project

You can train up to 20 employees for one fixed cost (this cost includes courseware and the instructors travel & lodging)

Our courses are full of games, simulations, and active learning to help the adult learner

SSDSI can customize the training to meet your company’s particular training needs

For More Information Contact: Kevin Clay, MBB at 866-922-6566 or kclay@sixsigmadsi.com

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