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Lean and Six Sigma Project Methodologies

(40 votes)

An introduction to five project methodologies (Lean, DMAIC, DMADV, DFSS & PMI) and when to use each.

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15 comments

  • Comment Link Matt Hansen Aug 1, 2016 posted by Matt Hansen

    Thanks, I'm glad you like it Ashish! Thanks for using StatStuff and for the kind feedback!

  • Comment Link Ashish Alva Jul 19, 2016 posted by Ashish Alva

    Thanks for the good work Matt. Really appreciated.

  • Comment Link Matt Hansen Apr 4, 2016 posted by Matt Hansen

    Thanks Isabel - I really appreciate the feedback and am glad you liked it!

  • Comment Link Isabel Soledad Apr 1, 2016 posted by Isabel Soledad

    Awesome! The best balance in theory and examples. Thanks for sharing!

  • Comment Link Matt Hansen Dec 31, 2015 posted by Matt Hansen

    Thanks for the feedback, Arif. Yes, there was a way to expand the videos to full screen, however, the code recently changed from my provider and removed that capability. I just got it fixed so by clicking on the arrows at the bottom right of each video it should expand it to the full screen.

  • Comment Link Arif Yildirim Dec 27, 2015 posted by Arif Yildirim

    Hi Matt,
    Thank you very much for sharing all these information for free.
    I have a very simple question: is there a way to watch the videos at full screen?

  • Comment Link Matt Hansen Aug 23, 2015 posted by Matt Hansen

    Siju, thanks for your feedback about StatStuff and checking out the site! I'm glad it's been a help to you.

    ASQ is one of the most popular sources for getting Lean Six Sigma (LSS) certified, however, that doesn't mean it's the "best". In my opinion, their cert requirements (like many other training orgs) are not very stringent and I've seen many folks get certified by them who were not at all capable of applying LSS; those folks knew enough to pass the exam, but had not practical application of LSS. And no, their requirement of completing a project or two is not sufficient; they do not validate the person's LSS skills nor the actual completion of those projects. Despite this critical gap, I don't necessarily think this means they're "bad" or not worth pursuing. I tend to advise only those who have already proven their application of LSS in real-world situations to pursue a cert from ASQ since they're an affordable choice. If you haven't already seen it, I recommend you check out this article I wrote that explains this in more detail: http://statstuff.com/resources/articles/straight-answers-about-lean-six-sigma-certifications.

    Based on my above comment, there's no particular book I'd recommend to pass the ASQ exam. I'd only recommend you find whatever resources help you learn the most and then apply what learned - that way you won't need to memorize answers to an exam, but your practical experience will be your best resource. But as for StatStuff, many folks have claimed that the StatStuff training content has helped them pass the ASQ exam (as well as exams from other training orgs). You're welcome to also use StatStuff's book that many folks love to use as a reference for what they learn in the videos (http://statstuff.com/products/book1). Regardless, you can't go wrong in pulling from many different resources to learn about LSS; I recommend using StatStuff (since it's free to use) and then for any gaps or for further study on any particular tool or topic, then just Google it for many other resources that may help you.

    Finally, if you haven't already seen it, I recommend you check out a comparison between all other LSS training organizations (http://statstuff.com/resources/training-organizations). This is the ONLY source that compares dozens of training orgs to let you easily see which one(s) best fit your needs.

  • Comment Link Siju George Aug 15, 2015 posted by Siju George

    Hi Matt,

    I am new to your site and find it extremely informative.
    I have recently completed APICS CSCP and now looking to pursue a six sigma certification from a reputed body/institute.
    I am based in Dubai and have zeroed in on ASQ.
    Will you be able to suggest how do I go about my preparation for the ASQ green belt.
    Can you suggest one book or some materials which would be comprehensive enough for my preparation for the ASQ Green Belt.
    Are the materials available on your website sufficient enough to prepare.

    Thanks in advance for your help.
    Siju George

  • Comment Link Matt Hansen May 28, 2015 posted by Matt Hansen

    Good question, Vamshi. Since you said it will affect the output of the body shells (which I presume means leading to sub-standard quality), then I would treat it as output-related and use Six Sigma (specifically DMAIC since it's an existing process). But since you know the root cause is the oven, then Six Sigma would be moot so you'd only need to fix the oven.

    In your situation, if the body shells are meeting quality standards, but you're finding the process is too slow and not keeping up with demand, then it would be more related to the process where you can use Lean to make that process more efficient (while hopefully still attaining your quality standards).

  • Comment Link vamshi Potluri May 24, 2015 posted by vamshi Potluri

    Hi Matt,
    In Process based shops efficiency and effectiveness are directly related, for example, if an oven in a paint shop is not working properly it will apparently effect the output of coated body shells.In most of the cases this proportionality will hold good.In these scenarios, which methodologies should we follow (Process related or output related)....???

  • Comment Link Matt Hansen Feb 9, 2015 posted by Matt Hansen

    Alexander - thanks, I'm glad to help!
    Ahmed - thanks for checking out the site. StatStuff's content is the same you'd get from most other GB or BB training organizations, so I'm not sure why anyone would want to pay for it when it's available here for free. I'm glad you're enjoying it!

  • Comment Link Ahmed Khaldi Feb 8, 2015 posted by Ahmed Khaldi

    Hi Matt.
    I responded to a linked post offering a chance to win a free access to a LSS GB course.
    this response was an opportunity for me to receive a mail from you inviting me to statstuff.com website.
    I register to statstuff.com and here I am enjoying all these free material.
    WOW.
    Really Great.
    Again, Thanks Matt.
    Best Regards
    Ahmed

  • Comment Link Alexander Titov Feb 3, 2015 posted by Alexander Titov

    Excellent, clear and very structural material!
    Thank you, Matt and your team!

    Best regards,
    Alexander

  • Comment Link Matt Hansen Jan 3, 2015 posted by Matt Hansen

    Thanks for the feedback! There's often a lot of confusing info on the different LSS methodologies. This particular video is designed to simplify the general distinctions between them. However, since there's no official body of knowledge on LSS, I wouldn't be surprised if there are variances in how different orgs teach or apply the different methodologies.

    The similarity here between DMADV & DFSS is that they are both used for developing something new (as opposed to Lean & DMAIC used for fixing something that already exists). The distinction is that DMADV is intended for a new process while DFSS is used for a new product/output.

    Despite how this layout defines the different methods in terms of their purpose or goal, it's not uncommon for each method (or any roadmap for each method) to also share many of the same tools/concepts between them. These are not meant to define rigid rules or a checklist for each method; common sense should always guide the application of these methods to ensure the goal of solving the problem comes well before trying apply every step in a process that may otherwise not make sense.

    I only have limited experience with DMADV & DFSS (my projects tend to primarily use DMAIC or Lean), so unfortunately I don't have any resources to reference. But I think a simple online search can yield some valuable resources.

    If anyone else has suggestions for good DMADV or DFSS sources, then please add a comment about it here. Thanks!

  • Comment Link Alexandr Zavialov Jan 2, 2015 posted by Alexandr Zavialov

    Dear Matt!


    This site is a great source of information.

    I need a clear understanding of different types of projects and corresponded methodologies next month. I've gain it.

    I have only one question:
    My previous believe was that DFSS employ usually DMADV project Roadmap, like Six Sigma employ DMAIC project cycle. In this case brick "Six Sigma use DFSS tools..."=brick "Six Sigma Use DMADV".

    Could You explain in more details how you differentiate this tools and roadmaps?

    or

    Could You direct me to sources of additional information, where I can find detailed information on issue/

    Thank You very much in advance

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Video List for Intermediate Path

Practical Ways to Apply Lean Six Sigma

Below are 36 videos (less than 10 hours of content) selected from the 121 videos in the Advanced Training Path. These videos go beyond the basics of Lean Six Sigma to help you apply the tools & concepts, but without getting as complex or detailed as the certification level in the Advanced Training Path.
1. StatStuff Orientation (What is StatStuff?)  
This video welcomes you to StatStuff by explaining some general concepts about how the videos are designed and how the site works.
2. Introduction to Lean and Six Sigma login not required 
An introduction to the fundamental concepts of the Lean and Six Sigma methodologies using the IPO model.
3. Lean and Six Sigma Project Methodologies login not required 
An introduction to five project methodologies (Lean, DMAIC, DMADV, DFSS & PMI) and when to use each.
4. Corporate CTQ Drilldown login not required 
A review of how to align a project opportunity to the overall business strategy and needs by understanding the business CTQs in a CTQ Drilldown.
5. Project Financial Benefits login not required 
A review of how to identify and categorize financial benefits from a project.
6. Prioritization Using a QFD Tool  
A review of how a Quality Functional Deployment (QFD) tool can be used to prioritize items, such as project opportunities.
7. Project Pre-Assessment Using a Min/Max Analysis login not required 
A review of why it’s important to do a project pre-assessment and how to do it using a Min/Max Analysis.
8. Key Roles in a Lean or Six Sigma Project login not required 
A review of the project and functional roles in Lean Six Sigma projects like Green Belt, Black Belt, Sponsor, Champion, etc.
9. Developing a Project Strategy Using IPO-FAT Tool login not required 
A review of how to build a strategy for a project and how the IPO-FAT tool can be used for developing that strategy.
10. Introduction to Lean  
An introduction to Lean including a brief history, the philosophy of Lean, and a summary of some common Lean tools and concepts.
11. Problem Resolution Using DMAIC  
A review of how the DMAIC methodology follows the typical steps we follow when trying to resolve a problem.
12. The DMAIC Roadmap (Levels 1 & 2) login not required 
A high-level roadmap through the DMAIC methodology that navigates the user through the various tools and concepts for leading a Six Sigma project.
13. Adapting Lean to Six Sigma DMAIC Flow login not required 
A description of how the Lean tools and concepts can be adapted to the Six Sigma DMAIC methodology.
14. Define Phase Roadmap (Level 3)  
A detailed roadmap through the Define phase of the DMAIC methodology that navigates the user through the various tools and concepts for leading a Six Sigma project.
15. Measure Phase Roadmap (Level 3)  
A detailed roadmap through the Measure phase of the DMAIC methodology that navigates the user through the various tools and concepts for leading a Six Sigma project.
16. Analyze Phase Roadmap (Level 3)  
A detailed roadmap through the Analyze phase of the DMAIC methodology that navigates the user through the various tools and concepts for leading a Six Sigma project.
17. Improve Phase Roadmap (Level 3)  
A detailed roadmap through the Improve phase of the DMAIC methodology that navigates the user through the various tools and concepts for leading a Six Sigma project.
18. Control Phase Roadmap (Level 3)  
A detailed roadmap through the Control phase of the DMAIC methodology that navigates the user through the various tools and concepts for leading a Six Sigma project.
19. Risk Analysis: The Reason We Use Statistics login not required 
A review of the importance of risk in our decision-making and how statistics can be used to measure that risk.
20. Analysis of Behavior & Cognition (ABC) Model  
A review of the ABC model that explores how we think so we can understand the risks and evidence behind our decisions and how to influence others.
21. Transfer Function login not required 
A review of the transfer function and the critical part it plays as a fundamental concept in the DMAIC methodology.
22. Hypothesis Testing: Overview login not required 
An introductory overview to an extended series about hypothesis testing. This lesson includes the general 4 step process used for hypothesis testing.
23. Overview of Statistical Terms and Concepts login not required 
A high-level review of the fundamental terms and concepts associated with statistics, such as population vs. sample data, distributions, etc.
24. Building a Problem Statement login not required 
A review of what a problem statement and background statement are and the characteristics of an ideal problem statement.
25. Defining the Project Y login not required 
A review of why we need to define a project Y and some methods for ensuring we’re defining the right project Y.
26. Identify Root Causes: C&E Diagram login not required 
An extension of the topic on identifying root causes using a cause & effect (C&E) diagram that will lead toward building a data collection plan (DCP).
27. Identify Root Causes: 5 Whys login not required 
An extension of the topic on identifying root causes using a 5 Whys approach that will lead toward building a data collection plan (DCP).
28. Identify Root Causes: C&E Matrix login not required 
An extension of the topic on identifying root causes by showing how the C&E Matrix is used after a C&E diagram and 5 Whys for building a DCP.
29. MSA: Overview login not required 
The first of an extended series on conducting a measurement system analysis (MSA) to help test the reliability of collected data.
30. Calculating a Sample Size login not required 
A review of how to calculate a sample size using a Sample Size Calculator.
31. Variation Over Time (Short/Long Term Data) login not required 
A review of short and long term data and the impacts that variation has over time.
32. Hypothesis Testing: Finding the Right Statistical Test login not required 
An extension on a series about hypothesis testing, this lesson reviews a chart that can help you find the right statistical test for your analysis.
33. Hypothesis Testing: Statistical Laws and Confidence Intervals login not required 
An extension on a series about hypothesis testing, this lesson introduces some statistical concepts that are fundamental to most hypothesis testing.
34. Hypothesis Testing: Proportions (Compare 1:1) login not required 
An extension on a series about hypothesis testing, this lesson reviews the 2 Proportions Test as a measurement of proportions.
35. Hypothesis Testing: Relationships (Overview) login not required 
An extension on hypothesis testing, this lesson introduces the concepts of a correlation and regression as part of measuring statistical relationships.
36. Hypothesis Testing: Relationships (Compare 1:1) login not required 
An extension on hypothesis testing, this lesson reviews the Pearson Correlation and Fitted Line Plot as part of measuring statistical relationships.

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