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Six Sigma Trends Six Sigma Leadership and Innovation Using Triz

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Six Sigma Trends: Six Sigma Leadership And Innovation Using TRIZ

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Six Sigma Trends: Six Sigma Leadership And Innovation Using TRIZBy Dr. Elena A. Averboukh The fourth installment in a series of articles about the on-going research of advanced strategies and trends in deploying and team-training Six Sigma.q q

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I am pleased to present another article on Six Sigma Trends that concerns enhancing traditional Six Sigma methodologies and tools with the systematic innovation management known as TRIZ (pronounced "TREEZ", the Russian acronym for the Theory of Inventive Problem Solving). In this article, a summary of current Six Sigma deployment roadblocks and limitations are identified. Many of these roadblocks can be eliminated with the use of TRIZ, which can lead to a much more advanced and productive version of Six Sigma. Finally, lessons learned from real-world training are shared. Why has it taken so long to accept and to start implementing TRIZ? Why only now is the interest growing at such a fast rate, especially within Six Sigma professional circles and deployments? The answer sounds obvious: We are currently facing a new reality when Voice of Customer has become a moving target which needs to be identified, predicted and influenced under growing competitive pressure. There is no time for traditional trial and error decision making methods and endless discussions. TRIZ may be the methodology "missing link" from your Six Sigma deployment.

Discussion Forum"I am involved in TRIZ (innovation theory) and I would like to know whether some of you have experienced the deployment of TRIZ mixed with Six Sigma methodology? What are the results of such experiments?" Sharing Six Sigma & TRIZ Experiences

Six Sigma Bottlenecks and New Demands for Future Deployments

Just-in-Time Six Sigma Deployment There are often significant delays in Six Sigma projects and intermediate deliveries. One of the most frequent reasonshttp://www.isixsigma.com/library/content/c030908a.asp (1 de 9)03/05/2005 2:46:10

Six Sigma Trends: Six Sigma Leadership And Innovation Using TRIZ

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is decision-making errors that lead to rework and time-consuming data collection activities. Other reasons are listed below in relation to Six Sigma project phases: Define/Identify Phasesq q q

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Poor project selection and/or problem formulation Non-exhaustive list of potential directions for change and/or for innovation Underestimated secondary problems which may arise during and/or as a result of primary problem solving Poor definition of alternative causes and effects and screening of significant inputs Failures caused by narrowing the scope of the projects in the wrong direction Non-exhaustive failure analysis

Measure Phaseq q q

Time-consuming data-collection and measurements Lack and/or high variability of measurement systems (Gage R&R) Failure in finding root cause

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Improve/Design Phaseq

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Lack of really productive and/or innovative ideas for improvements (upgrade to 4 sigma level and higher) or lack of competitive design or redesign Time and labor consuming DOE

Verify/Control Phasesq

Non-systematic and non-exhaustive failure prediction

These reasons lead not only to delays, but also increase the Cost of Poor Quality (COPQ) due to rework. Repeated idea collection, endless meetings and discussions, screening the alternatives, measurements and analysis also significantly deteriorate overall acceptance and support of further deployments. The need for additional efficient analytical techniques and tools, which not only accelerate the above decision-making activities but alsoq q q

make decision-making and problem-solving activities error-prone, increase their productivity and reduce cycle time, and increase Roll Throughput Yield of innovative and competitive solutions through the whole Six Sigma process,

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Six Sigma Trends: Six Sigma Leadership And Innovation Using TRIZ

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is apparent and urgent. Low Cost Six Sigma Small and medium size companies or business units, who actively enter the Six Sigma community, have additional limitations when deploying Six Sigma methodology:

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Personnel are limited and often working overtime. It is often difficult (if not impossible) to find suitable candidates for Black and Green Belt positions to lead Six Sigma projects on either a full-time or part-time basis. Resources, both financial and human, for Six Sigma projects are extremely limited. Black and/or Green Belts are often left to conduct their projects on an overtime basis. Innovative products and services are critical to business survival and should be introduced or updated as quickly as possible. Big capital investments are often avoided or postponed, even when their return on investment is very high and financial justification convincing.

Therefore, the need for a successful, just-in-time Six Sigma deployment becomes especially critical when:q q

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Methods and tools for efficient generating low-cost Six Sigma solutions must be readily available. Solutions have to be innovative and competitive if they relate to (re-)design of new product, technology or service. Cycle-time of Six Sigma projects must be further reduced. Costly errors in decision making, especially at the early phases of Six Sigma projects, which lead to rework (e. g., extra and/or redundant measurements), must be avoided.

Zero Defect Challenges For Forecast-Based Business Processes There are core business processes where the Cost of Defect or Failure is extremely high and critical to the overall business longevity. These include:1. Forecast-based business development strategic decisions r Should the company focus on new products or other growth strategies? r What role do new products play in the overall growth strategy? r Which know-how/processes should remain in the company and which one have to be outsourced? 2. Forecast-based intellectual property protection decisions r How should the company develop a high-quality patent umbrella, which provides long-term protection for the current and future product lines? r How should the company develop patents efficiently (within a reasonable time-scale and budget)?

The application of analytical tools, which support analysis of trends and patterns of market development, are in strong demand. Such tools are complementary to the quantitative data-driven statistical tools and also make use of qualitative data to analyze and predict further evolution of technology, market, etc.http://www.isixsigma.com/library/content/c030908a.asp (3 de 9)03/05/2005 2:46:10

Six Sigma Trends: Six Sigma Leadership And Innovation Using TRIZ

Detect and Eliminate Root Causes This is a typical task for any Six Sigma project. Nearly each company has some painful areas, where many man-years of multiple trials and errors and even application of Six Sigma tools did not lead to an insight into the root causes of problem areas. The application of alternative, e.g. I-TRIZ analytical knowledge-based tools for Anticipatory Failure Analysis and Prediction, supports efficient and effective problem solving in such situations.

TRIZ Can Help You Avoid Six Sigma BottlenecksTRIZ is an established science, methodology, set of tools, and knowledge- and model-based technology for stimulating and generating innovative ideas and solutions. It was invented by Henrich Altschuller, who published many books, technical publications, and patents on this topic from the early 1960s up to 1985. TRIZ basic postulates, methods and tools, including training methodologies invented by Henrich Altschuller have been further developed and significantly enhanced by his followers, researchers and trainers (from 1985 to present). These enhancements are known as the I-TRIZ generation of methodology and tools. TRIZ is ubiquitous in Eastern Europe, particularly in the countries of the former USSR. Since the early 1970s, TRIZ has been part of many university-, college- and school-education programs. Now, more and more European, and particularly German, universities in cooperation with industries successfully integrate TRIZ into their curriculum. Recently, it has been successfully used in different industries and also in Pacific countries. Originally TRIZ was primar