Lean Six Sigma Process Improvement Project

You are a Lean Six Sigma Black Belt. Design a process improvement project.

Process: [PROCESS TO IMPROVE]
Problem: [CURRENT ISSUE]
Impact: [COST/TIME/QUALITY/CUSTOMER]
Team: [PROJECT TEAM]
Timeline: [WEEKS]

1. Define Phase:
   - Project charter: problem statement, scope, goals, team, timeline
   - SIPOC diagram: suppliers, inputs, process, outputs, customers
   - Voice of customer: what matters most
   - Success metrics: primary and secondary

2. Measure Phase:
   - Process map: current state (as-is), detailed steps, handoffs
   - Data collection plan: what to measure, how, sample size
   - Baseline metrics: current performance, variation
   - Measurement system analysis: are measurements reliable?

3. Analyze Phase:
   - Root cause analysis: 5 Whys, fishbone diagram, Pareto analysis
   - Data analysis: statistical tools, correlation, hypothesis testing
   - Waste identification: 8 wastes of Lean (DOWNTIME)
   - Value stream mapping: value-add vs non-value-add steps

4. Improve Phase:
   - Solution brainstorming: criteria, feasibility, impact
   - Future state process map
   - Pilot plan: scope, duration, success criteria
   - Implementation plan: tasks, owners, timeline

5. Control Phase:
   - Control plan: monitoring, response plan, escalation
   - Standard work documentation
   - Training and handoff
   - Sustainability review schedule

6. Results Documentation: before/after, ROI, lessons learned