FAQs
WHAT DOES RCI STAND FOR?
Rapid Continuous Improvement. Rapid comes from the integration of lean six sigma, kaizen, project management and change management tools accelerate projects, to achieve the same goals in about half the time.
WHAT IS LEAN SIX SIGMA?
Lean Six Sigma is a process improvement methodology. Lean tools focus on eliminating waste to reduce cycle time, increase efficiency and lower inventory. Six sigma tools focus on understanding the voice of the customer, improving quality and reducing variation. The combined lean six sigma methodology, combined with project and change management, rapidly improves processes and create sustainable results.
WHAT IS DMAIC?
DMAIC is an acronym for the five stages of a lean six sigma project: Define, Measure, Analyze, Improve, Control.
What is Kaizen?
Kaizen is a compound Japanese word from “kai” meaning “change” and “zen” meaning “for the good”. So kaizen literally translates as “good change”. RCI Consulting defines kaizen as the rapid application of lean six sigma tools to a process. Kaizen has three stages: preparation, kaizen event, follow-up. There is a strong bias for action to complete the project faster, but there is also more risk since only basic analysis tools are used. RCI Consulting defines a kaizen event as an application of Lean Six Sigma (DMAIC), to get results in about half the time. The project has three stages: pre-work, kaizen event and follow-up.
1. Pre-work: Define and parts of Measure phase are completed in preparation, as well as detailed agendas and logistics planning for the kaizen week. This work is done with a small core team, typically two to six weeks prior to the kaizen.
2. Kaizen event: The rest of Measure, Analyze and Improve phases are completed. This lasts a full week (five days). The team develops solutions and a detailed implementation plan by Wednesday afternoon / Thursday morning that can be reviewed and approved by sponsor. The rest of the week is used to start executing as much of the implementation plan as possible with the team present (typically 40-60% by the end of the kaizen event).
3. Follow-up: Control phase is completed. Our experience is that 80% of the implementation plan can be completed within one to two months of the kaizen, which gets most of the benefits quickly.
The kaizen approach works equally well in manufacturing, transactional and commercial projects. Scope does not limit the ability to use kaizen, only the size of the team and amount of facilitation required.
WHAT IS LEAN?
Lean is the focus on eliminating non-value added waste, while preserving the activities that add value from the customer’s point of view. The lean tool set is also know as the Toyota Production System where many of the tools were developed, and are still used today. Tools and methods include 5S, Process Mapping, Value Analysis (TIMWOOD), Little’s Law, Process Efficiency, SMED, Replenishment Pull, Process Simplication, Process Flow Improvement and others. Benefits include lower cycle times and working capital, more flexibility and employee engagement.
WHAT IS SIX SIGMA?
Six Sigma is a process improvement methodology started at Motorola in 1985. The focus is understanding and reducing variation to improve quality. A six sigma process would statistically only product 3.4 defects per million opportunities. The five phases of six sigma are Define, Measure, Analyze, Improve and Control (DMAIC). Tools and methods include Chartering, SIPOC mapping, Voice of the Customer (VOC), statistical analysis, root cause analysis, failure mode and effect analysis (FMEA) and control plans. Benefits include lower costs, higher quality and capacity, increased customer satisfaction.
WHAT IS TIMWOOD?
TIMWOOD is an acronym for the seven forms of waste in a process. During value analysis of a process, TIMWOOD is used to help identify different sources of waste in a process for eliminate or reduction.
Transportation
Inventory
Motion
Waiting
Overproduction
Overprocessing
Defects
