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.
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.
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.
💡 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.
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.
🔗 Lean Six Sigma Green Belt
🔗 Lean Six Sigma Black Belt
🔗 Lean Six Sigma Yellow Belt
🔗 LEAN Certification
We offer a variety of flexible training options to fit your needs! You can learn at your own pace with our Online Self-Paced, On-Demand courses, including our free Online Lean Six Sigma White Belt. We also offer comprehensive online programs for Lean Six Sigma Yellow Belt, Green Belt, and Black Belt certifications. If you prefer in-person instruction, we can come onsite to your organization or you can join our public training sessions, available live virtually or in person at any of our 52 training centers. Every one of our courses can be delivered either live virtually or live in person, ensuring you get the learning experience that works best for you.
🔗 What is LEAN?
🔗 What Is Six Sigma?
🔗 What is a Green Belt?
🔗 What is a Black Belt?
🔗 What is a Yellow Belt?
For more information, ☎️ contact us: https://sixsigmadsi.com/contact-us/ or call us at 866-922-6566
(00:00) - Introduction to the Podcast and Guest Edriece Patterson
(01:28) - Edriece's Military Background and Introduction to Process Improvement
(02:42) - Using the Army Ignited Credentialing Assistance Program
(04:50) - Defining the Project: The Orders Publishing Process
(06:08) - Understanding Waste vs. Variation in a Process
(09:06) - The Measure Phase: How the Process Baseline Was Calculated
(10:55) - The Analyze Phase: Using Design of Experiments (DOE) on a Transactional Process
(13:43) - The Shift to a Data-Driven Mindset
(14:49) - The Improve Phase: Adding Personnel and Creating a Standard Operating Procedure (SOP)
(16:37) - The Results: A Faster, More Consistent Process
(18:36) - Gaining Acceptance and Ensuring Long-Term Success
(20:03) - The Career Impact of a Six Sigma Black Belt Certification