DMAIC STANDARD WORK TEMPLATE DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 DMAIC STANDARD WORK TEMPLATE

DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 Please use this DMAIC Standard Work Template to help guide you in preparing a presentation that summarizes the key team based activities that drive both revolutionary and evolutionary improvement. Feel free to contact any of the following members of the Product Integrity Group listed on this board for help.

Define Measure Analyze Improve Control The DMAIC Model Guideline for Process Improvement Define Measure Develop Business case for project. Identify Owner Define Mandate Select Team & Team Leader Set Team Norms Determine Customer and Business needs Define critical Input, Process and Output measures Define Process Start & End Define Process Inputs & Outputs Determine Customer Requirements Map “As Is” Process Analyze Improve Control Benchmark as Needed Establish MFA data collection method Establish QCPC data Establish SPC data Gather Data Analyze current costs / potential savings Perform Waste analysis on “As Is” process. Understand process variation Understand process performance Implement Improvements / Mistake Proofing Devices Update Standard Work Implement Key Characteristics Monitor Metrics (Process KC’s & Customer) to Verify Improvement Document savings Share Lessons Learned ID potential future projects. Perform Root Cause Analysis on problems. Develop / select alternative solutions Map “To Be” Process Develop Action Plan Management Review Pilot changes and validate improvement Establish direction and accountability. Understand current process. Baseline Process Performance Understand Process Opportunities Pilot and Validation of Improvements Standardized Improvements

TEAM BASED DMAIC PROCESS Collect data SPC, QCPC & MFA Map information/ process flows Process Management Select Opportunity Develop Team Mandate 2. Measure 1. Define 3. Analyze Root Cause Analysis Why? 5. Control 4. Improve Repeatable Effective Efficient Standard Work Mistake Proof

Measure Analyze Improve Control Define Display Process Improvement Status Measure Analyze Improve Control Define Develop a visual method to display the overall ACE Process Improvement activity within the work group. Recommended format based on the DMAIC model For each activity, give status on progress within each of the 5 areas: Define, Measure, Analyze, Improve and Control.

Type PROJECT TITLE here DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 Type PROJECT TITLE here Type Date here Put a picture of the part here (if applicable)

DMAIC Project Summary Define, Measure, Analyze, Improve and Control Define key metric trying to improve Define team players Define key process steps (flowchart) Define key measures (i.e., Key Characteristics) Control Measure DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 Summarize the types of Mistake-Proofing controls used to control the variation over the long term Describe any B/P changes, SPC Key Characteristics added, and Control Plans instituted Describe the type of data that was collected at this step in the project Describe characteristics of the data collection Describe the measurement system used to collect the data Improve Analyze Summarize the both process and product improvement ideas brainstormed at this step in the DMAIC process Describe some of the improvement tools used such as DOE, Waste Elimination, PFMEA, etc. Describe the analysis tools & techniques used by the team at this point (RRCA, Fishbone analysis, etc.) Summarize the Team’s conclusions (i.e., capability too low, accuracy off location, yield too low, cycle time too high, etc.)

Problem Describe here briefly the project PROBLEM 5 4 3 2 1 CONTROL DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 Describe here briefly the project PROBLEM

Objective Describe here briefly the project OBJECTIVE. DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 Describe here briefly the project OBJECTIVE. You may show the top level metric chart here that your team is trying to improve. What is the Team attempting to accomplish?

Project Mandate On this page put a copy of the Team Mandate that DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 On this page put a copy of the Team Mandate that is supported by management. Examples are CQE Project Contract Sheets, Passport Job Tickets, and Supplier Investigation forms.

Part Function Describe here briefly the FUNCTION of the part DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 Describe here briefly the FUNCTION of the part if applicable using a bullet chart. Also include a picture of the unit.

Team List below the names of the TEAM members DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 List below the names of the TEAM members and their corresponding functions: Quality Engineer’s name Manufacturing Engineer’s name Design Engineer’s name Purchasing Buyer’s name Supplier Contact’s name Customer Contact’s name etc.

MEASURE Show a picture of the part feature that you are measuring. DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 MEASURE Show a picture of the part feature that you are measuring. Describe the measurement system employed to gather the data. Show examples of the data gathered from the process you are trying to improve. Show an example of the data collection sheet filled in or an Excel spreadsheet of the data.

ANALYZE 5 4 CONTROL 3 IMPROVE 2 ANALYZE 1 MEASURE DEFINE List on this page charts of the measurements such as the following: Histograms (include Cp, Cpk, Pp, Ppk for variable data) Run or Control Charts to see trends and patterns Pareto Diagrams that illustrate top turnbacks and/or defects to go after Statistical tests for accuracy or precision parameters etc. Minitab Analysis Example

IMPROVE DEFINE MEASURE ANALYZE IMPROVE CONTROL 1 2 3 4 5 List bullets of each improvement idea being explored by the team List bullets of each improvement idea completed by the team List bullets of improvement ideas currently in the process of being implemented with a status Show illustrations of the tools used to drive improvement. For example: Fishbone Diagram analysis Design of Experiments Process Failure Mode Effects Analysis etc.

CONTROL 5 4 CONTROL 3 IMPROVE 2 ANALYZE 1 MEASURE DEFINE Describe the Mistake-Proofing devices implemented into the process designed to control the variation, such as: LEVEL I: Physical devices designed into the process that prevent an error from happening at the source. LEVEL II: Warning devices such as Control Charts for SPC Key Characteristics identified for a particular process step, buzzers, alarms, etc., that depend on a human reaction for mistake-proofing effectiveness. LEVEL III: Methods implemented that detect a nonconformance prior to shipping it to the Customer.

Lost Cost Savings - The Final Result 5 4 CONTROL 3 IMPROVE 2 ANALYZE 1 MEASURE DEFINE Cost Avoidance Scrap dollars prevented in the future Warranty costs avoided into the future Etc. Customer Satisfaction