A good idea is not yet a proven solution. The pilotA limited, controlled launch of a solution in a small part of the process, to validate real-world performance before full rollout. Click term for full definition plan takes your winner to the GembaJapanese for "the actual place"; going to directly observe a process rather than relying on documents or memory. Click term for full definition, safely, and brings back the evidence your sponsor needs. Watch the short video, then work with the toolkit PDF: it explains the method, shows a worked example and gives you a blank template to fill in.
Tool video
The short tool video will appear here.
Pilot Plan in short
- Define the scope. Where, how long, who takes part, which metric you compare.
- Run a Pre-Pilot FMEAAn FMEA applied to a new solution before piloting it, to anticipate new failure modes it might introduce. Click term for full definition. New failure modes, severity, detection. High RPN? Back to I2.
- Build the roll-back planA contingency plan to immediately revert to the old process if a pilot reveals unacceptable risk. Click term for full definition. How to return to the old way instantly if things go wrong.
- Run and observe. Keep the observation log. Be a ghost, ask the naysayers, note near misses.
- Compare and decide. Pilot data against the baselineThe established, quantified level of current process performance for a specific metric (the Y) before any improvement efforts are implemented. It is the definitive benchmark against which all future results will be compared, ensuring the project's success and Return on Investment (ROI) are measured ... Click term for full definition. Go, adjust or stop.
Key points
- Small, controlled, time-boxed.
- FMEA and roll-back before you start.
- Observe the why, not only the what.
- Compare against the baseline.