In the world of business, problems occur. And it is good to know that many of them can be preventable using the right tools. And that is where process behavior charts come in. They are used in a wide variety of industries, especially in the manufacturing industry, for the purpose of finding out if a process is stable and in control. 

These charts visually monitor the performance of a process using a data-driven approach. And when they are used correctly, they can give you the ability to prevent problems from occurring in real time. In the instance of manufacturing, this means a company can eliminate problems like costly downtime. This makes process behavior charts an invaluable tool in that respect.

Besides that, process behavior charts can do so much more. Here are some of the other benefits.

Benefits of Using Process Behavior Charts in Organization

They tell you when something is wrong in a process

Sometimes it can be hard to tell when a process in trouble and needs to be amended. By looking at a control chart, you can be able to tell when it is time to make some improvements. That way, these charts serve as an early warning system, telling you when a process is about to misbehave.

As we know, in the world of manufacturing, producing a subpar product can be costly in many ways. For example, if your product is of low quality, you run the risk of disappointing customers, which can make them jump ship and seek out the competition. By using a process behavior chart, the problem can be identified it its infancy and corrected before it becomes a real issue.

They prevent unnecessary tampering of the process

Most times, a process behaves the way it should, meaning there’s no need to make any amendments. Tinkering with it would count as unnecessary tampering, which can cause it to misbehave. Tampering with it could accidentally leave it vulnerable to factors that can increase special cause variation, which is not the type of variation you want.

By looking at a control chart, you can make an informed decision in regards to the process; like when to avoid messing with what works. When a process is working correctly, the variation will be random along the center line. This is a good time to tell operators to do nothing and let it do what it does until the chart tells you otherwise.

They help you determine if your improvement efforts are working

Suppose you have a process that is not stable and is out of control. You can make amendments to it, but how can you tell whether your efforts have paid off? By looking at a control chart, of course. The chart can also alert you if your amendments are having the opposite effect; making the process worse rather than fixing it.

On top of assessing the impact of your amendments, process behavior charts can give you the power to predict the future output of a process. When a process is stable and in control, it can be predictable, This type of information can put you in a position to make informed decisions.

They eliminate guesswork when improving a process

Some people have a natural talent when it comes to fixing processes. This allows them to tell exactly what is wrong and how to fix it. These people operate by instinct, and by looking at a process behavior chart, they would just be confirming what their gut feeling has already told them.

However, not everyone has this innate ability, and to level the playing field, they can use a control chart. If they use their gut feeling in this scenario, they would be doing a lot of guesswork and probably fall prey to myths surrounding the performance of processes.

There are many tools that can be used to tell what is wrong with a process. Ensuring that all processes, especially in the manufacturing industry, are running smoothly is essential to customer satisfaction and gaining a competitive advantage. This is essentially what process behavior charts are for, which gives way to the above-mentioned benefits.

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What Does Lean Focus On?

Lean focuses on reducing the eight types of waste (Muda).  Defects, overproduction, waiting, non-utilized talent, waste from transportation, inventory waste, waste from motion, unnecessary processing. Additionally, Lean principles aim to reduce waste by identifying and eliminating it. Lean also improves production by maximizing flow and identifying non-value-adding steps you should remove. Anything that does not add value for the customer is a potential threat to production. As such, Lean uses a holistic approach that aims to build a culture of continuous improvement and in-depth analysis.

Lean Principles, Tools, and Techniques

• PDCA. Standing for Plan, Do, Check, Act, PDCA is a rapid cycle-based strategy used to drive process improvement.

• 5S is a 5-step method for creating and maintaining an intuitive and efficient workplace. The 5 Ss stand for Sort, Set In Order, Shine, Standardize, Sustain.

• 8 Types of Waste. Lean aims to eliminate the eight waste types: defects, overproduction, waiting, non-utilized talent, waste from transportation, inventory waste, waste from motion, and unnecessary

• Value Stream Maps. VSMs are a visual method for displaying the key process steps in production.

• Flow is the unhindered movement of a process.

• Pull describes how customer demand is used to dictate process flow, i.e. what the customer wants, or might want, determines what a company produces.

What does Six Sigma Focus On?

Six Sigma and Lean share many similarities. As such, they complement each other very well. However, Six Sigma focuses primarily on reducing variation, just one of the seven types of waste Lean tackles. Six Sigma is used to complete improvement projects, aimed at solving process issues. It is also highly data-oriented, involving validation of hypotheses using statistics. Six Sigma knowledge is classified using a belt-based hierarchy styled on martial arts (Yellow, Green, Black, and Master Black Belt). The higher the belt, the more adept you are at using Six Sigma. Furthermore, one of Six Sigma’s primary tools is a 5-step method with which to complete improvement projects.

Six Sigma Ideas, Tools, and Techniques

• DMAIC. This 5-step method uses the following steps, Define, Measure, Analyze, Improve, and Control to improve production processes. Furthermore, DMAIC also allows you to identify the problem and develop creative solutions through deep analysis.

• Project Charter. Six Sigma uses a single-page document to outline the process issue, project goal, scope, and a timeline. Moreover, the charter forms an essential framework for the trajectory of an improvement project.

• Pareto Chart. Pareto Charts display information about potential causes of process issues in a cascading bar chart format. Additionally, you should also organize problems from largest to smallest.

• Hypothesis Testing. Hypothesis Testing is a way of providing statistical precision to root causes of process problems, so you can make the best decisions.

• Design of Experiments. Methods of controlled testing, with which to assess how efficient processes are. DoE also allows you to select the best conditions, materials, and methods for each.

• Statistical Process Control. SPC enables you to monitor your processes, ensuring they consistently satisfy customer demand.

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Six Sigma Yellow Belt Curriculum

• Core Yellow Belt Techniques and Ideas 

  Our two-day course introduces process mapping (6-foot view), C&E matrices, effects analysis, failure modes, and fundamental statistics. Likewise, we teach how to comprehend and create SIPOC diagrams, as well as develop graphs. Software like Minitab is an essential tool in Six Sigma, which is why we provide a crash course in how to use it effectively.

• Competitive Strategy

  Six Sigma relies on several important principles to make the most impact on production process improvement.

1. Operational Excellence is a key principle in Yellow Belt curriculums, as it encourages businesses and production lines to operate at optimal levels. Yellow Belt curriculums should teach trainees how to implement OE processes to different types of enterprise. Ideally, OE principles should be taught in a practical and theoretical sense. That way, Yellow Belts will have the best of both worlds when it comes to Six Sigma skills. The practical expertise to make lasting changes towards process improvement, and the theoretical knowledge to back them up.

2. Customer Intimacy is another important principle in Yellow Belt training. On our Yellow Belt curriculum, we teach trainees how to understand value streams within businesses, as well as the many ways in which customer expectation and demand affects production. Yellow Belts should be able to identify areas that require attention, such as those affecting customer satisfaction. 

3. Product and Cost Leadership strategies also form an essential part of Yellow Belt work. Product Leadership pushes companies to produce innovative products and adapt existing services in a creative manner. Cost Leadership is similar in that it pushes a company to take advantage of market share by supplying quality products at competitive prices. Both strategies help to outdo competitors and position a company as leaders in cost and production. Yellow Belts should understand the fundamentals of both if they are to make any significant process changes. 

• Continuous Improvement (Kaizen)

  Additionally, Kaizen is a key mindset for businesses to have. Instead of letting processes fester and accumulate waste over time, employees should be taught to seek out and recognize problems as they occur. Using Yellow Belt knowledge, Six Sigma practitioners need to understand Kaizen and how it can drive lasting process changes. 

• Six Sigma (and Lean)

  Six Sigma and Lean forms the groundwork of all Yellow Belt work. All Yellow Belts should possess a strong grasp of Six Sigma’s fundamental methodologies. Yellow Belts should understand the value, attitudes, and goals of Six Sigma. Our aim is to incorporate more Lean elements into our courses, to help students realize effective improvements in practice. 

• Organizational Culture and Change Management

  Six Sigma demands teamwork, and project management and leadership skills are essential qualities in Yellow Belt training. While Yellow Belts occupy varying positions, they still form part of an important hierarchy which they must understand. In leadership roles, Yellow Belts should also be knowledgeable of Top-Down and Bottom-Up approaches to change management.

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