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Army Six Sigma Black Belt Project Eliminates Waste
In this episode of Why They Fail, host Kevin Clay speaks with U.S. Army Officer Edriece Patterson about his Army Six Sigma Black Belt project. The discussion highlights how Lean Six Sigma methodologies solve complex non-manufacturing challenges inside a military environment.
Edriece, a West Point graduate, recognized a chance to address the Army’s notorious “hurry up and wait” culture. He focused on streamlining a critical administrative task: the orders publishing process. By improving this workflow, the project became a powerful example of how Lean Six Sigma drives efficiency in transactional operations, not just factory floors.
The Challenge of an Army Process Improvement Project
While serving in his unit’s operations shop, Edriece identified waste in the orders process. Orders were received, crafted, and published with long delays and frequent rework. Inconsistent results meant that the same task could take hours longer depending on who handled it.
Before the project, publishing an order required an average of 6.75 hours. The large variation confirmed the process was unstable and out of control. This bottleneck consumed valuable time and slowed down critical Army operations.
Executing the Army Six Sigma Black Belt Project with DMAIC
Edriece applied the DMAIC framework (Define, Measure, Analyze, Improve, Control) to guide the project. During the Analyze phase, he used a Design of Experiments (DOE) approach. Although many assume DOE is only for manufacturing, he proved it is equally effective for administrative processes.
The DOE analysis revealed two main delay factors: operator experience and time spent waiting for review.
With these insights, the Improve phase delivered clarity. Edriece developed a robust Standard Operating Procedure (SOP) and trained more personnel to follow the same standard. Consequently, the average process time dropped to 6.25 hours. More importantly, variation decreased sharply, making the process reliable and predictable.
This successful Army Six Sigma Black Belt project shows that a data-driven strategy outperforms guesswork or opinion-based problem solving.
Key Takeaways from this Podcast:
Lean Six Sigma improves administrative and transactional processes, not only manufacturing.
Data-driven tools such as Design of Experiments deliver clarity that opinions cannot match.
Clear SOPs reduce variation and improve consistency across teams.
Cross-training personnel prevents bottlenecks and ensures operational resilience.
The Army Ignited Credentialing Assistance Program helps soldiers earn professional certifications like the Lean Six Sigma Black Belt.
A Word from our Sponsor, Six Sigma Development Solutions
.
This episode of Why They Fail is sponsored by Six Sigma Development Solutions, Inc., a global leader in Lean Six Sigma certification training.
We are an Authorized Training Organization accredited by the International Association for Six Sigma Certification (IASSC). Our programs have transformed more than 100 organizations across 52 countries, delivering over $100M USD in savings and certifying 4,000+ practitioners. Our trusted partners include Aerojet Rocketdyne, Dropbox, and Mercy Health.
Key Certification Training we provide:
Chapters
- (00:00:00) - Why They Fail: Continuous Improvement (
- (00:01:12) - Why They Fail
- (00:02:07) - How to Get Your Lean 6 Sigma Black Belt
- (00:05:12) - Waste in the 6 Sigma Process
- (00:12:55) - Experiential learning in the Army
- (00:15:30) - What kind of effect did it have on the process
- (00:17:48) - The DMAIC Process
- (00:21:44) - Why They Fail: Edris's Story
