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Generating Improvement Ideas

In the journey of Six Sigma, the Improve Phase is where creative solutions are born. It's a phase that demands innovative thinking to improve processes and solve problems identified in earlier stages. One of the crucial tasks in this phase is generating improvement ideas. Here's a guide to help you to understand and master this task.

Understanding the Context

Before diving into idea generation, it's essential to understand the problem thoroughly. The Define, Measure, and Analyze phases of DMAIC (Define, Measure, Analyze, Improve, Control) provide a solid foundation for this understanding. Ensure you're clear on what the problem is, why it needs solving, and the impact of its solution. 

1. Encourage Open and Diverse Thinking

The first step in generating ideas is to create an environment where creativity is encouraged. Diversity in thought is key. Involve team members from various backgrounds and expertise. Encourage participants to think freely, without constraints or fear of judgment.

2. Brainstorming Sessions

Brainstorming is a widely used and versatile group creativity technique designed to generate a large number of ideas for the solution of a problem. Developed in the 1930s by advertising executive Alex Osborn, brainstorming is based on the principle that a group of people can produce more and better ideas than individuals working in isolation. 

Key Concepts of Brainstorming:

  1. Quantity Over Quality: The primary objective of brainstorming is to generate as many ideas as possible. The focus is on quantity, not quality, under the premise that a large number of ideas increase the chances of producing a valuable and innovative solution.

  2. Withholding Criticism: During the brainstorming process, criticism and evaluation of ideas are suspended. This encourages open and uninhibited participation, as fear of judgment often stifles creativity.

  3. Welcoming Unusual Ideas: Encouraging wild or exaggerated ideas can lead to creative and out-of-the-box solutions. Even if these ideas are not directly applicable, they can serve as a springboard for other innovative concepts.

  4. Combination and Improvement: Participants are encouraged to build on or combine existing ideas. This collaborative approach can lead to more refined and comprehensive solutions.

  5. Creating a Conducive Environment: A comfortable and open environment is essential for successful brainstorming. Participants should feel relaxed and free to express their thoughts without fear of criticism or ridicule.

  6. Diverse Participation: Involving people from different backgrounds, expertise, and perspectives can enrich the brainstorming session, bringing a wider range of ideas and solutions.

  7. Time Limitation: Setting a specific time limit for the brainstorming session helps maintain focus and energy, ensuring that the activity remains dynamic and productive.

  8. Post-Brainstorming Analysis: After the brainstorming session, ideas are analyzed, evaluated, and refined. This stage involves critical thinking to assess the feasibility, practicality, and potential impact of the generated ideas.

  9. Facilitation: A skilled facilitator can guide the brainstorming session, encouraging participation, keeping the discussion on track, and ensuring that all voices are heard.

  10. Visual Aids: Using whiteboards, flip charts, or post-it notes can help in visualizing and organizing ideas, making the brainstorming process more interactive and engaging.

Brainstorming is commonly used in business, education, engineering, software development, and many other fields. It is a flexible tool that can be adapted to various group sizes and settings. The method is particularly effective in the early stages of problem-solving when generating diverse and creative solutions is more important than immediate practicality.

3. Utilize Six Sigma Tools

Several Six Sigma tools can aid in idea generation. For instance:

Cause-and-Effect Diagrams: Helps visualize the causes of a specific problem and thus spark ideas for solutions.

5 Whys Technique:By repeatedly asking 'why' a problem occurs, you can delve deeper into root causes, potentially unveiling innovative solutions.

TRIZ (Theory of Inventive Problem Solving):

TRIZ is an acronym for "Teoriya Resheniya Izobretatelskikh Zadach," which translates from Russian to "Theory of Inventive Problem Solving." Developed by Soviet engineer and researcher Genrich Altshuller and his colleagues in the 1940s, TRIZ is a problem-solving, analysis, and forecasting tool derived from the study of patterns of invention in the global patent literature. It is a methodology for systematic innovation that provides a structured approach to understanding and solving complex problems creatively. 

Key Concepts of TRIZ include:

  1. Patterns of Technical Evolution: TRIZ studies how systems evolve over time, identifying patterns and predicting future developments. This allows innovators to foresee potential problems and solutions.

  2. Inventive Principles and Standard Solutions: Altshuller analyzed thousands of patents and identified a small number of principles that are the basis of most inventions. These principles can be applied to find innovative solutions to new problems.

  3. Contradiction Matrix: One of the central ideas in TRIZ is that at the heart of many problems are contradictions (such as the need to make a material both strong and flexible). The contradiction matrix is a tool that helps identify and resolve these contradictions by suggesting principles that might overcome them.

  4. Ideality: TRIZ seeks the ideal final result of a problem-solving process, focusing on eliminating the shortcomings of the current system without making it overly complex or introducing new problems.

  5. Function Analysis: In TRIZ, problems are broken down into their most basic elements (functions) to understand them better and identify solutions.

  6. Resource Analysis: TRIZ methodology emphasizes using resources that are already present in the system or its immediate environment. This approach fosters cost-effective and efficient solutions.

  7. ARIZ (Algorithm for Inventive Problem Solving): ARIZ is a step-by-step procedure for solving complex problems that cannot be solved by simpler TRIZ tools. It guides the user through a series of steps to transform a situation with a problem into one without a problem. 

TRIZ is widely used in engineering, product design, and process improvement. It encourages thinking outside the box and can be applied to virtually any field to find innovative solutions to challenging problems. The methodology is especially beneficial for complex problems where traditional problem-solving methods fall short.

4. Look for Benchmarks

Sometimes, the best ideas are already out there. Look into how other companies or industries have solved similar problems. This benchmarking can provide valuable insights and inspiration.

5. Prioritize and Refine Ideas

After the initial idea generation, the next step is to sift through the ideas. Evaluate them based on their feasibility, impact, and alignment with the project's goals. Use tools like the Impact Effort Matrix to prioritize ideas.

6. Prototype and Test

For promising ideas, develop small-scale prototypes or pilot tests. This real-world testing can provide valuable feedback and highlight potential improvements or adjustments needed.

7. Foster Continuous Improvement Culture

Finally, cultivating a culture that values continuous improvement and innovation is crucial. Encourage team members to continually look for ways to improve processes and solve problems, not just in formal sessions but as part of their daily work.

Conclusion

In conclusion, generating improvement ideas in the Improve Phase of Six Sigma is a blend of structured methodology and creative thinking. It requires an understanding of the problem, an environment that fosters diverse and free-thinking, and the use of systematic tools to refine and test ideas. Remember, the goal is not just to solve the problem but to do so in a way that optimizes process efficiency and effectiveness.

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LSS_BoK_1.2 - The Fundamentals of Six Sigma

E) Improve Phase

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