Ten Steps to Process Improvement, Part 2

By Ronald D. Snee, Ph.D., Principal, Tunnell Consulting, Inc. As the first part of this article ( ) demonstrated, not all improvement programs have to come from top management. Numerous mid-level pharmaceutical manufacturing leaders have successfully initiated and executed process improvement projects that have enhanced operations, generated financial benefits and advanced their careers. How? By adhering to the following ten-step path, or a similarly proven framework for achieving and sustaining improvement. As the great pioneers of quality like Deming and Juran tirelessly pointed out, all work is accomplished through processes. Thus, advancement entails improving those processes. Therefore, you should begin by identifying the process most critical for the success of your function or department and pinpointing the need for improvement. Often the need for improvement is self-evident – discarded batches, frequent rework and wide variations in the process. Where the need is less clear, you can identify key performance metrics, collect data and identify gaps in the performance of the process. Most importantly, you must be prepared to show how those performance gaps adversely affect operational performance, the bottom line and other relevant measures, demonstrating what is possible and how improvement will benefit all stakeholders. As Arie DeGeus, former head of planning for Royal Dutch Shell says, “The ability to learn faster than your competitors may be the only sustainable competitive advantage.” That holds true both for organizations and for executives who want to excel in them. Don’t be afraid to learn and learn fast about the proven process improvement methodologies – Six Sigma, Lean and a combination of the two, Lean Six Sigma. Six Sigma is a quality measurement and improvement program. Its use promises dramatic gains in process excellence and helps reduce defects and errors; cuts cycle time; improves yield, service and compliance; increases customer satisfaction; and enhances the