Solution Selection & Risk Assessment – Choosing Improvements That Actually Work
1. The Problem It Solves
After thorough analysis, manufacturing teams often generate many improvement ideas. Technical solutions, process changes, automation options, and procedural fixes are proposed simultaneously. While enthusiasm is high, decisions become difficult.
Without a structured selection approach, solutions are chosen based on opinion, hierarchy, or perceived simplicity. Some improvements work temporarily but introduce new risks, complexity, or cost. Others fail because feasibility and side effects were not considered.
Solution Selection & Risk Assessment exists to solve this problem. It ensures that chosen improvements are effective, feasible, and robust, not just attractive on paper.
2. The Core Idea in Plain Language
Solution Selection & Risk Assessment is about making deliberate improvement choices based on evidence and risk awareness.
The core idea is simple:
Not every technically possible solution is a good solution.
Potential improvements are evaluated against criteria such as impact on CTQs, implementation effort, cost, risk, and sustainability. Risk assessment ensures that improvements do not solve one problem while creating another.
This discipline turns analysis into responsible action.
3. How It Works in Real Life
After Analyze and DOE activities, teams shortlist solution options that directly address validated root causes. These options are then compared using structured criteria.
Risk considerations often build on insights from FMEA, evaluating how proposed changes affect failure modes, detection capability, and process stability.
In manufacturing environments, this step helps balance performance gains with safety, quality, and operational constraints. Decisions are documented, assumptions are made explicit, and trade-offs are understood.
This structured decision-making creates alignment and confidence.
4. A Practical Example from a Manufacturing Environment
Consider a medium-sized manufacturer seeking to reduce defect rates on an assembly line. Analysis suggests several options: additional inspection, tighter tolerances, new tooling, or improved error-proofing.
Using structured solution selection, the team evaluates each option against impact, cost, implementation time, and risk. Error-proofing combined with minor tooling changes offers the best balance.
Risk assessment confirms that the solution reduces defect likelihood without increasing cycle time or safety risk.
The chosen solution delivers sustainable improvement without unintended consequences.
5. What Makes It Succeed or Fail
Solution selection fails when decisions are rushed or driven by authority rather than evidence. Skipping risk assessment often leads to rework later.
Another failure mode is over-analysis. Excessive evaluation can stall momentum.
Leadership behavior matters. Leaders must support fact-based decision-making and accept transparent trade-offs.
Successful solution selection creates clarity, commitment, and confidence.
How Solution Selection & Risk Assessment Connect to Other Six Sigma Tools
This step builds directly on Analyze phase insights, including Regression Analysis and DOE.
It uses FMEA to assess risk.
It prepares improvements for Pilot Testing and Standardization.
It strengthens the Improve phase by ensuring solutions are both effective and safe.
Closing Reflection
Solution Selection & Risk Assessment ensure that improvement efforts deliver real, lasting value. They replace impulse with intention and protect organizations from well-meant but harmful changes.
In manufacturing environments where changes affect cost, quality, and safety, this discipline is essential.
