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newer, but when the team had attempted to mix this formulation on the newer mixer, they were unable to produce a compound that met specification They had run some long-term capability studies and found it had a capability index Cpk of just over 033 one standard deviation from the closest specification limit In other words, the process was only at one sigma George had not figured out all of the statistics, but he had checked around, so he knew how bad it was By convention, a Cpk of less than one means a process is incapable of generating a product within specification limits In contrast, the Cpk for a six sigma process is 15 or greater George knew, then, that the new mixer, with its Cpk just over 033, would be far from good enough George and his supervisors had made the strategic decision to stay with the old mixer and the queue rather than use the new mixer and try to figure out how to separate the good material from the bad They also figured out that any extra capacity they gained would be lost while material piled up in front of the inspection process, not to mention what they lost to scrap I didn t want to make George feel any worse by trying to enlighten him to the fact that 100% inspection is not inspection, but sorting So I bit my tongue and then started asking questions Do you really think the issue is trying to squeeze extra capacity out of this machine or is the problem really the inherent capability Before he answered, I asked a follow-up Would it be easier to take a machine that has the ability to produce an adequate amount of material and focus on improving the capability George replied as I hoped he would I never really thought of it that way He paused, then explained, We usually just do inspection As I approached the mixer, it was apparent that the Five S fairy had dropped by Things were clean, organized, and labeled Good
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start Some of the noise was out of the system Processes were documented It looked like George was serious about the Five S and Work Standardization It wasn t my program any more: it appeared he had taken over ownership I was impressed The work that had been done was a good first step toward institutionalizing the two initiatives and making them the process for solving chronic organizational issues When the improvement process transitioned to the way SG did business, we would really be making progress I knew I could probably solve the mixer problem within a few days by myself, but then it would be my solution In order for this process to be meaningful, I needed to make the solution belong to George and his team They had to walk away from the situation believing that next time something like this surfaced they would be equipped to handle it successfully Before getting too deep with all the players as a team, I wanted to get up to speed on the process I began with the older mixer I drew a simple process map on a piece of paper, onsultants cannot blocked out the steps, and identified the solve Six Sigma various materials Projects for the organiThe tools and materials were sitting zation Members of the around the machine as inputs I also took organization must some time to review the other documents solve the problems for and controls, which were easily accessible themselves with the The process map I sketched wasn t a thing consultants help That of beauty with all the correct symbols and is the only way that true change can occur notations, but it was accurate in the organization By completing this rough, high-level map, I could introduce it at the first team meeting to help focus the group
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In a more traditional Black Belt project, such as I d worked on in the past, we would have taken the time to complete this task in a conference room with the team But involving everyone in the operation tended to be a longer process, followed by hours on the computer to make it look pretty
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