The CI Geek

How to approach problem-solving in 5 simple steps: DMAIC is a data-driven quality strategy used to improve processes. The acronym stands for: -Define -Measure -Analyze -Improve -Control It's an integral part of the Six Sigma methodology, but can also be implemented as a standalone process. Each phase has clear objectives, actions and outputs. Here is a DMAIC roadmap to drive your CI initiatives to the next level: PRE-WORK +Define the defect +Develop problem statement, goal and scope +Establish visible tracking metrics +Identify sponsor, process owner & team resources +Gain project approval *** DEFINE +Refine the project charter +Define the process - SIPOC +Identify and manage project stakeholders +Understand the Voice of Customer and Business +Develop a data collection plan for your Y *** MEASURE +Create a detailed process map +Check the data quality +Understand process behaviour +Compare baseline to process targets +Develop process measures *** ANALYZE +Analyze the process +Develop theories and ideas +Analyze the data +Verify root causes +Understand cause and effect +Quantify business impact of root causes +Establish pilot plans for solution sets *** IMPROVE +Execute pilot plans for prioritized solutions +Assess pilot results and risks +Select and recommend the best solutions +Plan for roll-out +Financial sign-off *** CONTROL +Implement and complete roll-out plan +Quantify the improvement & prove sustainability +Transfer of ownership and close the project +Final project & financial sign-off Understanding and adhering to DMAIC nature is the key to a successful Lean Six Sigma project. Credit: Kaizen Made Easy *** Continuous Improvement is 90% mindset and 10% toolset. While you focus on developing your mindset, we’re working hard to build KaizenHQ! KaizenHQ will handle your toolset from 0 to 100%. Do you wanna be the first to know when we launch it in Q3’2025? Join 100s of CI leaders on the waitlist here: https://lnkd.in/dmE-fJRJ

Standardize-Do-Check-Act Credit to Sergio. Give him a follow Want a stronger foundation for your team? Standardize first. SDCA builds trust and lasting systems. Stabilization secures progress. Yet many skip it before scaling. Why SDCA first? +It locks in success +It builds a stable base +It preps you for better PDCA cycles Step 1 ➟ Standardize ↳ Write down the new steps ↳ Train your team to follow them ↳ Stick to the same method every time Step 2 ➟ Do ↳ Follow the plan with care ↳ Fix errors as soon as they pop up Step 3 ➟ Check ↳ Match results with your goals ↳ Spot any flaws or gaps Step 4 ➟ Act ↳ Fix root causes ↳ Update the standards if needed ↳ Celebrate the wins as a team SDCA vs. PDCA? ↳ SDCA maintains stability ↳ PDCA sparks fresh progress ↳ Together, they drive real growth Why stabilize? ↳ It prevents backsliding ↳ It builds trust in new processes ↳ It sets a solid stage for big wins P.S. Ready to anchor improvements before scaling up? Start with SDCA! *** We’re pushing ourselves out of our comfort zone by building our first digital asset. KaizenHQ is coming in Q3'25! If you wanna grow your CI organization with an all-in-one workspace designed to +save you time +run more Kaizen initiatives +and drive more revenue Join the waitlist here: https://lnkd.in/dJdUqhR3

Are you aiming for Operational Excellence?   Learn to see Muda first.   Muda is a Japanese term meaning waste, that is everything the customer isn't willing to pay for.   The types of waste are:   1/ Overproduction 2/ Waiting 3/ Transportation 4/ Over-processing 5/ Inventory 6/ Motion 7/ Defects 8/ Underutilized human potential   How can you start recognizing them?   Standardized Work Chart is a crucial Lean tool.   It documents and visualises the best way to perform a specific process.   Key Components:   1/ Process Information  ↳ Basic details about the process   2/ Process Steps  ↳ A table to list the characteristics of each step   3/ Process Layout  ↳ A placeholder for a diagram of the work area   4/ Required Tools  ↳ A section to list necessary equipment and supplies   5/ Quality Checks  ↳ A place to note quality control measures   6/ Total Cycle Time  ↳ Recording of the overall process duration   7/ Approval  ↳ A section to ensure the chart is reviewed and approved.   Video Credit: Nilson Rodrigues da Silva *** We’re pushing ourselves out of our comfort zone by building our first digital asset. KaizenHQ is coming in Q3'25! If you wanna grow your CI organization with an all-in-one workspace designed to +save you time +run more Kaizen initiatives +and drive more revenue Join the waitlist here: https://lnkd.in/dJdUqhR3

How I sort and categorize a large number of ideas during Continuous Improvement initiatives: The Affinity Diagram is one of the most important technical tools to master as you progress through DMAIC. It's useful to brainstorm your solutions. Basic steps: 1. Brainstorming Ideas Each team member writes down one idea per Post-it note. Sticky notes are then posted randomly on a wall or whiteboard. *** 2. Idea Clustering As your team review the ideas out loud, they sort them into similar groups. The key is looking for natural relationships and affinities between the ideas. *** 3. Creating "Header" Cards The team create a header card for each group of related ideas. Header cards capture the common theme or category. This provides a high-level structure to organize the detailed ideas. *** 4. Reviewing and Refining The team discuss the header card. Adjustments are made to ensure each idea is properly sorted and categorized. *** Benefits: +Enhanced group creativity +Solid foundation to select solutions +Ideas organized into a logical framework Best Practices: +Follow brainstorming rules +Promote large participation +Capture all ideas, no criticism +Allow for multiple idea placements +Narrow down the solutions through multi-voting *** We’re pushing ourselves out of our comfort zone by building our first digital asset. KaizenHQ is coming in Q3'25! If you wanna grow your CI organization with an all-in-one workspace designed to +save you time +run more Kaizen initiatives +and drive more revenue Join the waitlist here: https://lnkd.in/dJdUqhR3

The Heart of Quality Management Credit to Harsh Thakkar. Give him a follow Original post below: It took me 10 years to understand: True quality management isn't about perfection; it's about continuous improvement. To achieve excellence in your organization, you must commit to ongoing enhancements: Want the highest quality products? ↳ Continuously gather and act on customer feedback. Want efficient processes? ↳ Regularly identify and eliminate inefficiencies. Want to make informed decisions? ↳ Base your actions on accurate and relevant data. Want a culture of improvement? ↳ Engage all employees in the process and value their contributions. Want lasting success? ↳ Balance small, incremental changes with breakthrough innovations. Continuous improvement is not about reaching a final destination. It's about constantly striving for better, every single day.

How to conduct an effective Gemba Walk Credit to Sergio. Follow him for more insights on CI. Original post below: The real work isn’t in the office. Discover the power of going to the source with a Gemba walk. Recently came across an excellent breakdown of Gemba - the Japanese concept meaning "the real place" where value is created. For leaders looking to improve operational excellence, here's the essential guide to conducting an effective Gemba walk: Before you start: • Set clear objectives • Notify workers in advance • Gather background information • Maintain an open mind • Bring the right tools The Core Process: 1/ Prepare your purpose 2/ Go to the Gemba 3/ Observe the process 4/ Ask questions 5/ Document findings 6/ Follow-up Key Principles • Go See • Ask Why • Show Respect Common Pitfalls to Avoid: • Acting as an auditor • Not engaging with the team • Rushing through the walk • Jumping to solutions • Interrupting workflows Smart Questions to Ask: "What challenges do you face with this process?" "What happens if something goes wrong?" "How do you think we can improve this?" "Why is this step necessary?" Remember: A Gemba walk isn't about inspection - It's about observation, understanding, and improvement through respectful engagement. *** Continuous Improvement is 90% mindset and 10% toolset. While you focus on developing your mindset, we’re working hard to build KaizenHQ! KaizenHQ will handle your toolset from 0 to 100%. Do you wanna be the first to know when we launch it in Q3’2025? Join 100s of CI leaders on the waitlist here: https://lnkd.in/dmE-fJRJ

Poka-Yoke Level: PRO Poka-Yoke is a Japanese term that means "error-proofing". It refers to any mechanism helping an operator avoid mistakes by preventing, correcting, or drawing attention to human errors as they occur. Here are 5 reasons why Poka-Yoke is key in manufacturing and beyond: 1/ Error Prevention Poka-yoke devices and techniques are designed to reduce the chances of producing defective products. *** 2/ Cost Reduction Defective products can result in rework, scrap, and warranty claims. All of them increase manufacturing costs. *** 3/ Quality Assurance Poka-yoke principles ensure products are manufactured according to specified quality standards and requirements. It leads to consistent quality, which is crucial for maintaining customer satisfaction and brand reputation. *** 4/ Operator Safety Poka-yoke devices are designed to prevent operator errors that could potentially lead to injuries. For example, safety mechanisms that prevent machinery from operating when guards are not in place. *** 5/ Process Simplification Poka-yoke methods often simplify systems and processes. They can lead to: +faster setups +work easy to do +clearer instructions +low training requirements *** Remember, Poka-Yoke is a powerful tool that can improve quality, productivity, and customer satisfaction. *** Continuous Improvement is 90% mindset and 10% toolset. While you focus on developing your mindset, we’re working hard to build KaizenHQ! KaizenHQ will handle your toolset from 0 to 100%. Do you wanna be the first to know when we launch it in Q3’2025? Join 100s of CI leaders on the waitlist here: https://lnkd.in/dmE-fJRJ

4 Six Sigma Key Metrics Credit to Govind. Give him a follow Six Sigma is not just a methodology — it’s a data-driven approach to process excellence. At its core lie metrics like DPU, DPMO, PPM, and RTY. These metrics are essential for +quantifying process performance +driving improvements. Let’s dive into each metric with examples and insights: 1/ DPU - Defects Per Unit Definition: Average number of defects found per unit produced Example: If 30 units are produced with 60 defects, DPU = 60 / 30 = 2 Insight: ➟ A lower DPU indicates higher product quality ➟ Reduce DPU by improving process controls and defect prevention *** 2/ DPMO - Defects Per Million Opportunities Definition: Number of defects per million opportunities Example: For 10 forms with 15 fields each and 26 defects DPMO = 173,333 Insight: ➟ DPMO is the backbone of Six Sigma levels ➟ A Six Sigma process targets 3.4 DPMO *** 3/ PPM - Parts Per Million Definition: Defective parts per million units produced Example: In a batch of 200,000 units with 400 defective PPM = 2,000 Insight: ➟ PPM directly measures defective units ➟ It’s crucial for supplier quality performance ➟ A lower PPM reflects better compliance with quality standards *** 4/ RTY - Rolled Throughput Yield Definition: The probability that a process produces a defect-free unit through all steps Example: For a four-step process with yields of 0.98, 0.95, 0.90, and 0.80 RTY = 0.98 * 0.95 * 0.90 * 0.80 = 0.67 or 67% Insight: ➟ RTY highlights the cumulative impact of defects across process steps ➟ Focus on improving yield at every step to boost overall RTY Why These Metrics Matter: DPU, DPMO, PPM, and RTY provide a view of process quality and performance. By tracking these metrics, you can +identify areas for improvement. +drive defect reduction. +ensure consistent delivery of high-quality products. P.S. How you leverage these Six Sigma tools to drive CI? *** Continuous Improvement is 90% mindset and 10% toolset. While you focus on developing your mindset, we’re working hard to build KaizenHQ! KaizenHQ will handle your toolset from 0 to 100%. Do you wanna be the first to know when we launch it in Q3’2025? Join 100s of CI leaders on the waitlist here: https://lnkd.in/dmE-fJRJ

Kaizen Mantra: Go see, ask why, and show respect. Image Credit to Govind Tiwari. Give him a follow The Gemba Walk is a vital practice in Lean Management. It’s about going to the Gemba, observing processes, engaging with teams, and driving improvement. When done effectively, it can +foster collaboration +uncovers hidden inefficiencies, +and builds a culture of excellence. Golden Rules of Gemba Walk 1/ Go to the Gemba First Start by observing where the actual work is happening 2/ Check the Gembutsu Examine tools, materials, and processes in action. 3/ Take Temporary Actions Address immediate concerns to maintain operations 4/ Find the Root Cause Use tools like the 5 Why’s to dig deeper into problems 5/ Standardize to Prevent Recurrence Implement long-term solutions for sustainability. Your data can lie. Go see the reality on the ground. *** Continuous Improvement is 90% mindset and 10% toolset. While you focus on developing your mindset, we’re working hard to build KaizenHQ! KaizenHQ will handle your toolset from 0 to 100%. Do you wanna be the first to know when we launch it in Q3’2025? Join 100s of CI leaders on the waitlist here: https://lnkd.in/dmE-fJRJ

Continuous Improvement is 90% Mindset, 10% Toolset. But what is the most powerful tool in your toolbox? Well, your eyes. We humans are visual creatures - our eyes take in information very quickly. Visual management is used to: +Share information +Set new work standards +Provide workflow transparency Some visual tools are: +Status Boards with metrics for goals +Kanban Cards to limit work-in-progress +Gantt Charts to illustrate project timelines So, if you make things visual in the workplace, it gets easier to spot issues, track progress and work better as a team. Now go out there and count the sheep! *** Continuous Improvement is 90% mindset and 10% toolset. While you focus on developing your mindset, we’re working hard to build KaizenHQ! KaizenHQ will handle your toolset from 0 to 100%. Do you wanna be the first to know when we launch it in Q3’2025? Join 100s of CI leaders on the waitlist here: https://lnkd.in/dmE-fJRJ