Dear Friends,
Can we improve six-sigma project handling better?
How to integrate innovation with six-sigma?
How to use six-sigma with TRIZ?
Six-sigma is one of the most systematic approaches of problem solving whereas TRIZ contains best possible solution set of historical problems.
I am sharing here one of key finding from my doctorate research for better application of six sigma by master black or black belt or green belt level of applicant.
Why?
The results of a questionnaire based survey of experts of six-sigma in Indian manufacturing sectors reveals that
- Most of six-sigma users were not aware of innovation tools of TRIZ.
- The average frequency for use of innovation tools is found to be approximately a value of 1 whereas most of statistical and graphical tools have frequency of use more than 4 in a scale of 1-5 in most of completed projects.
Use of Quality Tools in Six Sigma Projects
Use of right tool for right purpose is one of key need for six-sigma, therefore, most of six-sigma training program focuses extensively on tools of six-sigma.
- Six-sigma training mainly includes team-tools, process-tools and statistical tools (Henderson and Evan, 2000). Team and process tools are used to prepare the six-sigma project leader with the required team building and leadership skills for the implementation of project. Both statistical and process tools may be used to ensure that the correct data are collected and transformed into which can be used to assist with the decision making process (Antony et al., 2006).
- Hagemeyer et al. (2006) addressed the issue related to tools of six-sigma and classified 20 key tools of six-sigma to develop problem solving matrix.
- Basu (2004) identified inadequate training, insufficient management commitment of resources and employee mindset are problem factors for effective application of tools.
- Antony (2004) pointed out that in some cases data are expensive, in other cases no data available to start with.
- Snee (2004) also pointed out that there is a need to improve the six-sigma methodology and develop new and better method in future. Six-sigma is based on statistical thinking and grounds on the logics of data to take decision, however innovation is equally or more desirable for breakthrough problem solving.
- Bresciani (2009) presented the relationship between creativity and innovation within firms in the Piedmont area. Improvement of the identified variables can be achieved using inventive problem solving combined with traditional engineering methods (Malinin, 2010).
About TRIZ
- To achieve breakthrough results through six sigma projects, innovation is required to be a part of solution. TRIZ, the Russian acronym of the ‘Theory of Inventive Problem Solving’ is a useful tool that can solve the problem of ”how to do” effectively in the innovative design process (Wang et al., 2005).
- As per French psychologist Antwan Ribaut creativity peaked at age 18 and then decreased for the rest of a person’s life. It is very discouraging fact for the organizations. Years after Genrich Altshuller, creator of the Theory of Inventive Problem Solving (TRIZ), replicate Ribaut’s study and found more distressing news with age for creativity coming down to 14 years (Terninko et al., 1998).
- As per the study of Boris Zlotin’s creativity reduces with age because of children’s overloading with information and diminishing belief in fairy tales, which are full of inherent contradictions.
- TRIZ is specialized in eliminating contradictions, systematic innovation is not only possible, but highly effective.
- TRIZ offers concepts and tools which lead in new direction, turning psychological inertia into a whirlwind of new ideas- it gives a gentle smack on the forehead, often creating more alternative ideas than one care to consider (Terninko et al., 1998).
It is to be noted that children are creative, but do not have the necessary knowledge to invent. Adults have knowledge, but have lost their natural creativity. Truth can help to acquire knowledge without losing creative imagination. Table shows the difference among adult and children thinking. It also provides the direction of TRIZ based thinking process.
TRIZ is a methodology based on US patent system and can effectively bring out innovation logically. Many of the roadblocks of six-sigma can be eliminated with use of TRIZ (Averboukh, 2003). It is needed, as the theory based on the features of great inventions and the pattern of evolution of system, rather than approaches with no theory, based on the psychology of people (Rantanen and Domb, 2008).
Through TRIZ, it is possible to generate concept for improvement of system by reducing negative effects. It is a very powerful tool, which can be applied on nearly all phases of entire product life cycle (Busov, 1999).
Altshuller studied 200,000 patents and selected 40,000 patents as representing the most effective solution. According to him, evolution of an engineering system is not a random event, but governed by certain patterns. Inventiveness and creativity can be taught. Altshuller’s early work on patents resulted in classifying inventive solutions into five levels, ranging from trivial to new scientific breakthroughs (Altshuller, 1999). Excellent results can be achieved by using six sigma methodology for problem solving. It is worth mentioning that every unsuccessful project reduces the commitment of management most of times because of high cost involved per project.
There is need to integrate six sigma with other quality tools to improve its ability and to solve problem more economically. Many researchers had felt the need to improve six-sigma by integrating it with other quality tools. The theory of inventive problem solving (TRIZ) is one of such powerful methodology.
How to Integrate TRIZ with Six Sigma
The TRIZ tools can be of great help to bring innovation systematically in framework of six-sigma.
Based on through study of properties and ability of TRIZ-tools, a DMAIC (stands for Define, Measure, Analyze, Improve and Control) and DMADOV integrated tool kit is developed as shown in Figure below:
Boosting Tools of Six Sigma
Previously, methodology to implement TRIZ is confined to design problems; however TRIZ tools can be of great help in manufacturing processes. Some of TRIZ tools help to think beyond the boxes which accelerate thinking process.
So let all readers check the proposal.
Kindly take action to test the application of suggested model in your problem solving approach.
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Stay blessed, Stay tuned
Ashish Soti
