I can’t tell you how many times I’ve heard, “We don’t have the data for this. I guess we’ll need to make an educated guess.” In the lean Six Sigma engagements I work on, my response to this is, “Let’s create the data.” Without fail, I get the deer-in-the-headlights stare for a couple of seconds until I explain what I’m proposing.

Below are some of the tools you can use to deal with situations when there are no data.

Manual data collection forms

Once you have created a value-stream map or just a regular process map, you should have identified the primary metrics to capture. Most metrics deal with time, quality, and cost across the value stream. Metrics—e.g., queue time, rework, defects, processing time—often are not captured in a system. Although you have a few ways of collecting the data, such as asking employees performing the work for their best estimate, the data are likely to be biased. You can also do what I do: Undertake a data collection exercise with employees for 10 to 15 days.

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