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5. Step 3 - Creating Predictable Processes

Step 3 - Creating Predictable Processes

This step focuses on the creation of stable and reliable processes with a predictable outcome the main objective of creating stable processes is to avoid incidents stream firefighting downtime, unsafe situation, quality spills, mistakes, etc. In other words the creation of an environment where you know what will happen and what can be promise do the client. Remember that reliable delivery date is better than a faster, but than a faster, bit unreliable delivery date. For this you will need stable and predictable processes.

This stage has high focus optimizing the logistics in work environment, rather than focusing on quality improvement programs. However creating stable and reliable process where people only focus on adding value and elimination of waste the quality of the product will increase as well. In this stage, there are hardly any difference between a production or an office environment as long as you continue to think in terms of process, the advantage of a production environment is that the results of this process (the products) are physically present, while in an office setting the results of the process (the service) is very often hidden in a computer system.

The five principles of Lean are the starting point in this level. Processes are described and established in an efficient manner by the identification and elimination of waste in the process. One of the most powerful tools used in this level is value stream mapping. Another programme that is very powerful for creating stability is Total Productive Maintenance (TPM). TPM is a strategy to improve the efficiency of available production resourced and to reduce machine-related rejections. TPM is mainly used in production environments that are highly machine dependent like automotive and food.

Besides Lean and TPM also TOC (Theory Of Constraints) is  an improvement approach that is often used at this stage, toc focuses on bottlenecks in the process or organization. TOC is also called bottleneck management or constraint management.

Other Topics

What is Six Sigma?
Why does Lean Six Sigma Go Hand in Hand?
Step 1 - Setting the House in Order for Lean Six Sigma Transformation
Step 2 - Creating a Continuous Improvement Culture
Step 3 - Creating Predictable Processes
Step 4 - Six Sigma Implementation - Statistical Process Control
Step 5 - Design for Six Sigma (DfSS)
Short Interval Management
What is DMAIC?
What is Kaizen?