Lean Six Sigma Tools and Templates

NOTE: This page is under construction as of Sept 2023, but we are working on it!

Here is a list of most of the tools and templates you may need for process improvement projects and events.

If you need help with any of these approaches, or would like some training on these tools and methods, check out our Lean Six Sigma coaching program.

Six Sigma Project

Projects are ideal for improving quality, reducing defects, variation reduction, transfer functions and prediction modeling, conducting experiments, and solving more complex problems.

We recommend using the DMAIC roadmap for your improvement project (“What is DMAIC?” video)

Preparation (selecting a potential project)

• Here are some project examples and ideas to consider
• Project Prioritization (video)

Define (defining a problem to improve and launching a project)

• DMAIC Project Checklist (template)
• Voice of Customer (VOC)
• Project Charter (template)
• Cost of Poor Quality (COPQ) (training slides)
• Calculate baseline sigma level (optional) (article)

Measure (reviewing the current process, observing, interviewing employees and validating data)

• Process Mapping
  • Process Variables Mapping or Input Process Output Variables Analysis (article)
  • Process Flow Diagram
  • Swimlane Map
  • Value Stream Mapping (VSM)
• Data Collection
  • Cause and Effect Matrix
  • Surveys (article)
• Statistical Methods
  • Mean and Median
  • Range and Standard Deviation
  • Distribution Fitting
    • Normal (Gaussian) distribution
    • Nonnormal distributions (lognormal, Weibull, etc)
• Pareto Chart (article)
• 8 Types of Waste (TIM WOODS) (slides)
  • Gemba Walks (article)
• Failure Modes and Effects Analysis (FMEA) (training slides | template | tips and tricks article)
  • Action Priority (AP) Table
• Measurement System Analysis (MSA) (training slides | course)
  • Gage Repeatability and Reproducibility (R&R) Studies (template | article #1 | article #2)
  • Attribute Agreement Analysis (Article)
• Capability Analysis (Cpk/Ppk) (training slides | article #1 | article #2)
• Capacity and Throughput Analysis

Analyze (getting to the root cause or quantifying the primary variation sources)

• Root Cause Analysis (“What is Root Cause Analysis?” video | training slides | article)
  • Cause and Effect (Fishbone) Diagram (article)
  • 5 Why’s
• Statistical and Graphical Analysis
  • Popular Charts and Graphs
    • Scatter Plot
    • Box Plot (article | guide)
    • Pareto Chart (article)
    • Multi-Vari Chart
    • Individual Value Plot
    • Time Series Plot
  • 2-sample t Test
  • Analysis of Variance (ANOVA) (course)
  • Multiple Regression Analysis (course)
  • Chi-Square Test (article)
  • Confidence Intervals (article)

Improve (implementing changes to the process and validating with data)

• Multi-voting and solutions matrix (video)
• Waste Elimination and Standardized Work (course | book)
  • Improve flow
  • Establish pull and kanban systems (course | book)
  • Eliminate/combine steps (article)
  • Reduce setup time (SMED)
  • Reduce batch sizes (batching vs one piece flow) (article)
  • Level loading
  • Rearrange work sequence
  • Reduce floor space
  • Reduce travel distance (article)
• Design of Experiments (DOE) (course)
• Calculate p-values and critical values for statistical tests (Statistical tables) or use a statistics software like Excel, Minitab or JMP or SigmaXL
• Mistake (error) proofing
• Training and Standard Work
  • Training Within Industry (template)
  • Cross-training Matrix (template)
  • What to do if you have excess resources after improvement?
• Visual Management
  • Mood magnets
  • Andon Lights
  • Kanban (size calculator template)
  • QDIP (SQDC) Sheets (template)
• Behavior Change (article)

Control (ensuring long term results and data monitoring plan)

• Process Control Plan (template)
• Statistical Process Control (SPC) (training slides | advanced course | article)
  • Continuous Data
    • Individuals and Moving Range Chart (template #1 | template #2)
    • X-bar and R/S Chart
    • CUSUM Chart (template)
  • Attribute Data
    • P/NP and C/U Charts (template)
• Daily Management System (huddles)

Report (quantifying hard and soft financial impacts and customer results)

• Project Documentation (template)
• Hard vs Soft Savings (“Calculating Financial Savings” video | article)

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Kaizen Burst or Rapid Improvement Event

Lean events are ideal for quickly moving through a project, but getting the right people in a room (or virtually) who are dedicated and empowered to resolving a well-defined problem.

There are three primary kaizen or rapid improvement events:

• Planning Event
  • Process Mapping – lower level process
  • Value Stream Mapping – from customer request to customer receipt
• Working Event
  • Kaizen Blitz – working session to resolve major problem in a process area
  • “What is a kaizen event?” video
  • Green your lean event article

Which lean event type should I do first, Value Stream Mapping or Kaizen Burst?

To begin planning an event, the first decision is to decide what type of event to conduct. If you are looking for immediate results and have clear problems you want to resolve, select the kaizen blitz event.

If you want to evaluate the process to determine where improvements need to be made, then a planning event should be conducted.

Here is the general process for conducting an event:

• Define event deliverables
  • Process Mapping – Current State Value Stream Map, Future State Value Stream Map, 90-day Action Plan
  • Value Stream Mapping – Current State Map, Ideal State (article), Future State Map, Action Plan, 90-day Action Plan
    • “What is a Value Stream Map (VSM)?” video (data box template | data box post-its)
  • Kaizen Blitz – Current State Map, Future State Process Map, Actions completed (80% during event), 30-day Action Plan (20% remaining)
    • “What is a kaizen event?” video
    • 5S Workplace Organization (training slides | electronic 5S course | assessment tool | 5s and KonMari article | Green your 5S event | books | products | electronic 5S course | red tags | pegboard organizer)
• Complete Lean Event Planning sheets
  • Event Charter
  • Establish ground rules
  • Determine event attendees (article)
• Schedule event dates
• Confirm attendance to event
• Event preparation kickoff and follow-up
  • Event Facilitator Supplies
• Prep training before event
• Event Plan
  • Gemba Walk (Energy Treasure Hunt)
• Report Out
• What to do if you have excess resources after improvement?
• 30-60-90 Day Action Plan

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Lean Transformation

Ideal for selecting a product or service family, determing the goals and objectives to improve performance, and using value stream mapping to understand the entire system, capture current, ideal and future state maps, then apply process improvement tools through a series of kaizen blitz events.

What is a Value Stream Map (VSM)?

• Define the product or service family you’d like to focus on
  • Not sure? Consider creating a Product Family Matrix
• Create a SIPOC diagram
• Create a VSM Event Charter
• Schedule a VSM event
• Prepare for the VSM
• Conduct the VSM event
  • Current State Map
  • Ideal State Map/Principles
  • Identify wastes and opportunities
  • Prioritize opportunities
  • Future State Map
  • Implementation Plan
    • Define and execute Kaizen Blitz events
  • 30/60/90 Day Reviews
• Capture results after 6-12 months
• Repeat, or identify another product or service

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If you need help with any of these approaches, or would like some training on these tools and methods, check out our Lean Six Sigma coaching program.