Process Improvement begins with understanding processes so they can be addressed using a controlled and systematic approach. Management must show a commitment by providing the requisite training and support to assure that process improvement practitioners have the knowledge and skills to employ a kit of tools or techniques, and effective use of these tools and techniques requires their application by the people who actually work on the processes.
The tools and techniques most commonly used in process improvement are:
- Basic Problem Solving
- Effective Problem Solving Techniques
- Design of Experiments (DOE)
- Advanced Design of Experiments
- FMEA (Failure Mode and Effects Analysis)
- Advanced FMEA
- Advanced Product Quality Planning
- Essential Statistical Methods
- GR&R (Gauge Repeatability Reproducibility)
- Supply Chain Management
- Project Management
- Kaizen Events
- Lean Healthcare
- The Lean Enterprise
- Lean Supply Chain
Application consulting services are available to support clients in the application of various process improvement and statistical methods. Here are a few examples of how our clients benefited from QSG consulting services:
- Design Failure Mode & Effects Analysis (FMEA). Our consultant facilitated several rounds of FMEA to a client’s new design. Subsequent feedback indicated that our assistance led to the most successful new product release to date.
- Process FMEA. Three days of support were provided to help a client transfer a process from their California plant to a new facility in Massachusetts. High first-pass yields were achieved in record time!
- Design of Experiments (DOE). A supplier of aeronautical parts was experiencing a bottleneck in its CNC operation. During a QSG Introduction to DOE seminar, our instructor helped a cross-functional team to design an experiment to improve the CNC process. In the wake of the experiment, throughput increased by 30% and within weeks all back-orders to a major customer were eliminated.
- Advanced Problem Solving/Root Cause Analysis. One client experienced an unexpected problem during a new product development project that dragged on and delayed the project for over a year. Another client experienced an unexpected and catastrophic field failure just after releasing a new product. Our consultant facilitated applications of systematic root cause analysis with both clients and the root causes were identified and verified within just a few weeks after our visit.
Consulting services like these are available to support the application of the methods taught in all of our process improvement seminars.