1. TM 720: Statistical Process Control DMAIC Problem Solving
IENG Lecture 02
DMAIC Problem Solving
2/21/2018
IENG 451 Operational Strategies
(c) D.H. Jensen & R.C. Wurl

2. IENG 451 Operational Strategies
DMAIC Overview
This is the step-by-step cycle of activities that Six Sigma improvement processes follow
Engineers use models methodically – this is it!
It is an acronym for:
Define
Measure
Analyze
Improve
Control
2/21/2018
IENG 451 Operational Strategies

3. DMAIC Implementation Options
Project Team Approach (Full DMAIC)
Team members (besides a Team Leader) include:
Suppliers to the process
Customers of the process
Operators in the process
Engineers & Supervisors (as needed)
Black Belt Sensei (as needed)
Typical time frame is 1 – 4 months
Team work on the project is part-time around other tasks
When the team works on the project, it is focused, fast
Whole team works on ALL phases
2/21/2018
IENG 451 Operational Strategies

4. DMAIC Implementation Options
Kaizen Approach (Rapid DMAIC)
Team membership is same as before, but:
Define (and some Measure) may be done beforehand by the team leader and a sub-team
Full team participates full time during Kaizen
Typical time frame is one week or less
Team work on the project is FULL-time, NO other tasks
During kaizen, the whole team works INTENSELY as possible
Whole team works on ALL REMAINING phases
Full scale implementation often happens after the kaizen event
2/21/2018
IENG 451 Operational Strategies

5. DMAIC Process in Detail
Define
Purpose:
Get agreement with sponsor (management) and team on:
Problem, Scope, Goals, Finances, and Performance Targets
Outputs:
Final Project Charter (purpose for project, resources)
Documentation of affected customer needs (VOC)
SIPOC or high level process diagram
Project Plans (scope, timing, deliverables, responsibilities)
Team consensus on project
Consensus is not unanimous agreement, it is unanimous support
2/21/2018
IENG 451 Operational Strategies

6. DMAIC Process in Detail
Define
Key Steps:
Project Charter review, revision & acceptance
Validation of Problem Statement
Validation of Financial Benefits
Validation of Process Map
Plan for Communication
Document Project Plan
Define Step ends with a Gateway Review
Outcomes: Go to Measure / No Go (terminate) / Return to Define
2/21/2018
IENG 451 Operational Strategies

7. DMAIC Process in Detail
Measure
Purpose:
Understand process Current State and collect data on:
Speed, Quality, and Costs to find Assignable Causes
Outputs:
Value Stream Map of the Current State
Reliable data on KPIVs and KPOVs
Obtain baseline measures, such as:
Process Capability, Lead Times, Sigma Level, Cost of Quality
Refined estimates of Improvement Goals
Demonstrably capable Measurement System
Refined Project Charter
2/21/2018
IENG 451 Operational Strategies

8. DMAIC Process in Detail
Measure
Key Steps:
Make & check process Value Stream Map
Identify KPIVs and KPOVs
Create data collection & analysis plans
Analyze measurement system
Collect data and establish baselines
Compute lead times, process capabilities & update VSM
Make quick, simple improvements – if warranted by data!
Measure Step ends with a Gateway Review
Outcomes: Go to Analyze / No Go (terminate) / Return to prior
2/21/2018
IENG 451 Operational Strategies

9. DMAIC Process in Detail
Analyze
Purpose:
Reduce data, verify / eliminate hypotheses and ultimately
Find the Assignable Causes
Outputs:
Document efforts and potential causes
Document data, analyses, and build case for links between KPIVs and KPOVs
Identification of Value-Added and Non-Value-Added work
Estimate Process Cycle Efficiency
2/21/2018
IENG 451 Operational Strategies

10. DMAIC Process in Detail
Analyze
Key Steps:
Perform a Value Analysis
Calculate Process Cycle Efficiency
Analyze process flow & identify bottlenecks, yield, rework
Analyze data collected in Measure Step
Generate theories (hypotheses) to explain relationships
Test hypotheses and validate theoretical models
Collect additional data and verify Assignable Causes
Analyze Step ends with a Gateway Review
Outcomes: Go to Improve / No Go (terminate) / Return to prior
2/21/2018
IENG 451 Operational Strategies

11. DMAIC Process in Detail
Improve
Purpose:
Pilot test and refine selected solution(s)
Execute a full-scale implementation
Outputs:
For Quality Improvement Projects:
Tested, robust solutions for the existing process, and
Eliminated Assignable Causes
For Lean Improvement Projects:
Documented results for best practices, and
Operating plans for the newly improved system
An Improved process!
2/21/2018
IENG 451 Operational Strategies

12. DMAIC Process in Detail
Improve
Key Steps:
Develop potential solutions
Evaluate and select best solution(s)
Optimize best solution(s)
Develop Next State value stream Map
Develop, implement, and validate pilot solution
Develop and implement full scale solution
Improve Step ends with a Gateway Review
Outcomes: Go to Control / No Go (terminate) / Return to prior
2/21/2018
IENG 451 Operational Strategies

13. DMAIC Process in Detail
Control
Purpose:
Complete project work and transfer solution(s) to owner
Maintain gains and identify checks to prevent regression
Outputs:
Documented transition plan
Documented means for training and operating process
Before and After process performance data
Monitoring system for the implemented process
Completed process improvement metrics and lessons learned
2/21/2018
IENG 451 Operational Strategies

14. DMAIC Process in Detail
Control
Key Steps:
Develop supporting method documents
Launch full-scale implementation
Lock in performance gains and monitor implementation
Develop process control plans
Audit results
Validate financial & performance results
Improve Step ends with a Gateway Review
Outcomes: Finalized project/ No Go (terminate) / Return to prior
2/21/2018
IENG 451 Operational Strategies

15. IENG 451 Operational Strategies
The big question is …
DMAIC – do we have to?
No …
Sometimes the solution is obvious and simple*
Sometimes you can get lucky*
Sometimes you can be rewarded for just working harder*
Because FAILURE is always an option.
Indicators that you should follow the process:
The problem has high complexity
The stakes of success/failure risk are high
The Obvious & Simple can’t be demonstrated with data
2/21/2018
IENG 451 Operational Strategies

16. TM 720: Statistical Process Control
Questions & Issues
See Dr. Jensen if you have not yet completed the information card or if you still need a syllabus.
2/21/2018
IENG 451 Operational Strategies
(c) D.H. Jensen & R.C. Wurl