Make It Work Before You Scale: Piloting Solutions in the Improve Phase

In the Improve phase of the DMAIC (Define, Measure, Analyze, Improve, Control) cycle, your team has already identified root causes and developed potential solutions. But before implementing those solutions across the entire process, it’s essential to test them through a pilot. A well-executed pilot minimizes risk, validates benefits, and builds confidence among stakeholders. Let’s explore how to carry out a successful pilot step-by-step.

1. Define the Objective of the Pilot

The first step is clarity. What are you testing—and why? A pilot isn’t about testing everything; it’s about validating key assumptions about your solution. Clearly define:

• The goal (e.g., to reduce rework by 30% in the order entry process)

• The metrics to evaluate success (e.g., defect rate, cycle time, customer satisfaction)

• The scope—which process, location, or team will be part of the pilot

A narrow, well-defined scope ensures quick learning without disrupting full-scale operations.

2. Select the Right Pilot Site or Group

Choose a representative environment where results will be meaningful. Ideal pilot sites have:

• A manageable scale (small enough for control, large enough for validity)

• Supportive stakeholders and open communication

• Data availability to measure impact. If the process spans multiple locations or teams, start with one unit before expanding.

3. Develop a Clear Pilot Plan

A detailed plan increases the likelihood of success. Your plan should include:

• Roles and responsibilities of all team members

• Timeline with key milestones

• Resources (people, tools, materials, budget)

• Training needs for operators or users involved.

• Data collection plan for before, during, and after the pilot

Document your plan and get approval from key stakeholders before moving ahead.

4. Communicate and Prepare the Team

Communication can make or break a pilot. Explain:

• The purpose of the pilot and how it aligns with improvement goals

• What’s expected of each participant

• How data will be collected and used. When people understand the “why,” they’re more likely to cooperate and provide honest feedback.

5. Run the Pilot and Monitor Performance

Execute the pilot according to plan. Keep close watch on:

• Process stability: Is the new solution performing as intended?

• Key metrics: Are you observing measurable improvements?

• Unintended effects: Are new issues arising? Collect both quantitative (data-driven) and qualitative (user experience) feedback.

6. Evaluate Results Objectively

After completing the pilot, compare results against your baseline and objectives. Ask:

• Did the solution achieve the desired impact?

• Were there any side effects or resistance?

• Is the change sustainable and scalable? Use tools like control charts, hypothesis tests, or before-and-after comparisons to validate results statistically.

7. Refine and Prepare for Full Implementation

Few pilots are perfect the first time. Adjust based on findings—fine-tune processes, address resistance, or modify the solution. Once validated, develop a rollout plan that includes standardization, communication, and training strategies for organization-wide deployment.

Conclusion

A successful pilot is not a trial run—it’s a learning opportunity. It allows Lean Six Sigma practitioners to confirm effectiveness, minimize risk, and build momentum for change. By following a structured approach—define, plan, communicate, execute, measure, and refine—you can ensure your Improve phase leads to sustainable, organization-wide success.