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PROCESSCERT™ DELIVERS THE FAMOUS SIX SIGMA RESULTS WITHOUT THE INFAMOUS SIX SIGMA BAGGAGE

What is the best way for a company to effectively handle Continual Improvement, without having to spend the high start-up costs for a full Lean Six Sigma program? How about the small to medium-sized companies that don’t have the manpower to run a full Lean Six Sigma deployment?

The SGS Business Process Optimization team is working closely with one of the fastest growing Process Excellence consultancies in Europe. Processfix Ltd. offers a unique method of process improvement training which is proven to deliver big results. Using a series of business simulation exercises, trainees are introduced to common but effective process improvement tools and techniques. The result is that participants are more likely to retain the training material because they have actively participated in its implementation.  

SIMULATION WORKS
Simulations have been used in many industries for decades. The most common example is probably flight simulators but the principles and the reasons for business simulations are parallel. Simulations allow participants to practice various events or roles in the safety of the laboratory or training room. Deficiencies can be identified and exposed in a “safe” environment which does not expose customers to unnecessary process modifications.  Once a process is refined it can be piloted and released for implementation, audit and certification.

SGS is using fixit kits developed by Processfix to run business process simulations during the workshops. Each process simulation session is run as a purely interactive event based around a simulated back-office process. Every delegate is allocated a role to perform, while some work as internal customers. Workshop Attendees generally run through multiple rounds of the simulation, each time measuring the improvement they generate by applying the process improvement tools they have learned.  In this manner, workshop attendees can learn and then quickly get process improvement tools “ingrained” by making their own process improvements during the workshops.  

PROCESSFIX™ vs. LEAN SIX SIGMA
In truth, much of what Processfix delivers is based on Lean and Six Sigma. The real difference is in the presentation and the packaging. Jake Allen, SGS Sector Head for Business Process Optimization Team says, "The methods used by Processfix are highly innovative and fun for the participant. However, being fun is not enough for business leader's to keep paying for these courses. They must continue to deliver financial return on the investment. It really is a win-win as the employee values the experience of attending and the business recognizes value from the new found process performance."  

Traditional Lean Six Sigma deployments involve specialist “belt training” to a relatively small percentage of the work force. The subsequent projects often take months to complete and leave themselves open to many classic difficulties such as resistance to change and poor project management. Conversely, the Processfix methods are highly inclusive and designed for all staff to attend. The participants collect the necessary data and also take active part in making and controlling the changes which are required to achieve better performance. This ownership is critical to the long term success of the process improvements.

A representative from Standard Chartered Bank recently noted: "The event allowed our managers to cut through the jargon associated with process improvement allowing them to recognize issues and take action to streamline them for our customers."

SEE FOR YOURSELF
SGS holds one and two-day workshops designed to give attendees a brief introduction to basic process improvement tools. During a typical 2-day workshop, attendees learn some key tools such as Project Chartering, listening to the "Voice of the Customer", determining items "Critical to Quality", Data Collection & Sampling plans, Process Maps, Failure Modes & Effects Analysis, Pareto Analysis, Fishbone (Cause & Effect) Diagrams, Root Cause Analysis, Control Plans, and more.

The regular ProcessCert product offers businesses training in conjunction with certification for whatever process is causing a company "Pain", from manufacturing to accounting. Since workshops are conducted onsite at the client’s facility, they can be completely customized to the needs of the client. The ProcessCert™ training typically starts with a two-day onsite workshop for the management team. The workshops are a great team-building exercise and a chance for management to begin thinking about the continuous improvement function within the business. Workshops culminate with many new tools learned and agreement on areas of the business most in need of improvement.

Next, in a focused two or three-day session SGS and Processfix™ trainers work with the client team involved in the actual process in need of improvement, to teach them the necessary continuous improvement methodologies, and deliver an improved process with defined customer requirements, measurements, and control plans. If the client desires, SGS then later follows up to audit the improved processes, assist with any additional process refinements, teach additional improvement tools as needed, confirm that stated goals are consistently achieved, and ultimately certify the process. This can be leveraged internally as well as externally to customers as “proof” of effectiveness and commitment to quality.  

The entire timeline from initial management training until final process audit and certification can be completed in as little as 12 weeks. According to Allen, "The process is highly repeatable. Clients may exercise the product once to solve a specific or immediate need, or use it in multiple areas or embrace it comprehensively as a Continuous Improvement mechanism to satisfy ISO 9001 Clause 8."

ProcessCert™ is ideal for companies who do not have the resources or initial investment to start a full-blown Lean Six Sigma program, but still want to learn the process improvement tools and techniques to reduce process variation and improve performance.

For more on Processfix's Fixit® simulations or SGS's ProcessCert™ contact Brad Thorne at E-mail

Brad Thorne, Master Black Belt
SGS North American Six Sigma Program Leader