Mastering Six Sigma: Ensuring Process Improvement with Measurements

A Six Sigma project has reduced the variability in a process. What should be done to facilitate further reductions in variability?

• A. Perform a measurement system capability re-analysis
• B. Develop a control plan
• C. Hold a brainstorming session
• D. Perform a failure modes and effects analysis

Answer: (A)

The correct choice centers around performing a measurement system capability re-analysis. Once a Six Sigma project has successfully reduced variability in a process, it is crucial to ensure that the measurement system is capable of detecting and quantifying that reduced variability effectively. A re-analysis of the measurement system capability allows for the verification that the measures being used are precise and accurate enough to reflect any changes made during the improvement efforts. This step is vital because if the measurement system is not sufficiently capable, it could lead to misleading conclusions about the ongoing improvements and variability. Ensuring the measurement system is robust allows the organization to confidently track further improvements and maintain the gains achieved in the project. Contextually, while developing a control plan is important for sustaining improvements and monitoring processes, it does not directly facilitate further reductions in variability. Instead, it helps maintain the new level of performance achieved. A brainstorming session can generate ideas, but it is typically not a systematic approach for addressing variability. Performing a failure modes and effects analysis is also beneficial in identifying potential issues in processes but is more focused on risk management rather than directly facilitating reductions in variability. Thus, the initial focus on measurement system capability is key to future improvement.

When embarking on the journey toward Six Sigma Green Belt Certification, one question inevitably catches many students off guard: “After reducing variability in a process, what should be your next move?” You see, this is a critical juncture, and the right answer can steer your project toward further improvements or leave it floundering in a state of uncertainty.

The best course of action here? It’s to perform a measurement system capability re-analysis. Think of this step as your safety net. Once your Six Sigma project has made strides in reducing variability, you need to ensure your measurement system is up to the job of detecting those changes. It’s like an athlete refining their skills; without a solid coach (that’s your measurement system), they might not hit their peak performance.

Now, let’s take a moment to connect the dots. The crux of the matter is that a robust measurement system is your ticket to understanding and quantifying any remaining variability. If those measurements are off, they can lead to some rather misleading conclusions about how things really are—which is the last thing you want after all that hard work! With a capable measurement system in place, you can confidently track the ongoing improvements, ensuring all those gains aren’t merely a fleeting triumph.

You might be wondering, “What about developing a control plan?” Sure, that's vital, but it plays a different role. Think of it as the follow-up plan. Yes, it’s important for maintaining the improvements you’ve achieved, but it doesn’t directly address the further reduction of variability. It’s like putting a nice, shiny bow on a gift instead of actually ensuring the gift is something of value.

And what about brainstorming sessions? They can certainly generate fresh ideas, but they often lack the systematic approach needed to tackle variability effectively. It’s a bit like throwing spaghetti at the wall to see what sticks—fun, but not particularly reliable.

Then there’s the failure modes and effects analysis (FMEA). This tool is fantastic for risk management; however, if we’re focusing on variability, it doesn’t hit the mark. Instead, FMEA is about identifying potential issues before they derail your process, not tweaking it for improved performance.

So, here’s the thing: when you focus on measurement system capability, you’re putting the big pieces in place to ensure your continuous improvement journey is on solid ground. Each piece of the Six Sigma puzzle plays its own part, but for taking your improvements to the next level, understanding and re-evaluating your measurement system should definitely be at the forefront of your mind.

In this journey, remember—consistent growth isn’t just about what you implement today. It also hinges on how well you can measure its impact tomorrow. Those who take the time to get this step right place themselves not only ahead of the game but also on a path of sustainable excellence.