Supercharging DMAIC IT’S TIME TO USE THE POWER OF THE COLLECTIVE MIND

2 1. Complete Project Charter Tools:  Charter: - Business case - Opportunity Statement/ Goal Statement  Project Scope  Project Team, Project Plan  Preliminary Problem Statement 2. Specify customer and business requirements Tools:  VOC/ VOB  Stakeholder Analysis  CTQ Tree  Kano Model  Change Management  Elevator Speech 3. Complete high level SIPOC Tools:  Block Diagram  5S  SIPOC Define Tollgate Sign-Off: Contract between the sponsor and team as to what they are going to work on 4. Identify what to measure Tools:  FMEA  C&E Matrix  Data Collection Plan  Functional Process Map  VA/ NVA Analysis  Value Stream Mapping  TAKT Analysis 5. Plan and collect data Tools:  Data Collection Plan  Operational definitions  Measurement System Analysis  Sample Size 6. Determine process baseline capability Tools:  Process Capability  Pareto  Descriptive Statistics  Control Chart Quick Wins / RIP? 7. Refine problem statement Tools:  Fishbone Diagram  Brainstorming  Five Whys  Value Stream Analysis 8. Rank key causes of variation Tools:  Descriptive Statistics  Stratification  Graphical Analysis  Value Stream Analysis  FMEA 9. Validate root causes Tools:  Graphical Analysis  Pareto Quick Wins / RIP? 10. Generate, prioritize and select solution ideas Tools:  Brainstorming  5S  Poka Yoke  Rapid Setup  Pull Systems 11. Validate impact of solution(s) Tools:  Should be process map  Cost/ Benefit Analysis  Multi-voting  Solution selection matrix  FMEA 12. Develop full scale implementation report Tools:  Project Plan  Pilot  Solution implementation report  FMEA Engineer Tollgate Sign-Off: Proposed solutions validated and implemented 13. Institutionalize the solution Tools:  Change Management  Stakeholder Analysis  Process Capability  Process Control Plan & dashboard  Signed off benefits  Control Charts 14. Replicate and share best practices Tools:  Project Database  Lean Sigma Network 15. Celebrate Tools:  Project Database  Lean Sigma Network  Celebrate Control Tollgate Sign-Off: Solutions institutionalized and offered for replication Quick Wins / *RIP/ Kaizen 1.0 Define Opportunities 2.0 Measure Performance 3.0 Analyze Root Causes 4.0 Improve 5.0 Control Performance 1.0 Define Opportunities Phases Reviews (tollgate meetings) Traditional Lean Sigma Toolkit and Methodology-DMAIC

3 1. Complete Project Charter Tools:  Charter: - Business case - Opportunity Statement/ Goal Statement  Project Scope  Project Team, Project Plan  Preliminary Problem Statement 2. Specify customer and business requirements Tools:  VOC/ VOB  Stakeholder Analysis  CTQ Tree  Kano Model  Change Management  Elevator Speech 3. Complete high level SIPOC and clean up Tools:  Block Diagram  5S  SIPOC Define Tollgate Sign-Off: Contract between the sponsor and team agreeing on project scope and goals. 4. Identify what to measure Tools:  FMEA  C&E Matrix  Data Collection Plan  Functional Process Map  VA/ NVA Analysis  Value Stream Mapping  TAKT Analysis 5. Plan and collect data Tools:  Data Collection Plan  Operational definitions  Measurement System Analysis  Sample Size Calculator 6. Determine process baseline capability Tools:  Process Capability  Pareto  Descriptive Statistics  Control Charts Quick Wins / RIP? 7. Refine problem statement Tools:  Fishbone Diagram  Brainstorming  Five Whys  Value Stream Analysis Tools:  Descriptive Statistics  Stratification  Graphical Analysis  Value Stream Analysis  FMEA 9. Validate root causes Tools:  Graphical Analysis  Pareto Quick Wins / RIP? 10. Generate, prioritize and select solution ideas Tools:  Brainstorming  5S  Poka Yoke  Rapid Setup  Pull Systems 11. Validate impact of solution(s) Tools:  Should be process map  Cost/ Benefit Analysis  Multi-voting  Solution selection matrix  FMEA 12. Develop full scale implementation plan and execute Tools:  Project Plan  Pilot  Solution implementation report  FMEA Engineer Tollgate Sign-Off: Proposed solutions validated and implemented 13. Institutionalize the solution Tools:  Change Management  Stakeholder Analysis  Process Capability  Process Control Plan & dashboard  Signed off benefits  Control Charts 14. Replicate and share best practices Tools:  Project Database  Knowledge management process  Lean Sigma Network 15. Celebrate! Tools:  Project Database  Lean Sigma Network  Appropriate Cultural Rewards and, or Recognition Control Tollgate Sign-Off: Solutions institutionalized and offered for replication Quick Wins *RIP/ Kaizen? 1.0 Define Opportunities 2.0 Measure Performance 3.0 Analyze Root Causes 4.0 Improve & Innovate 5.0 Control Performance 1.0 Define Opportunities Phases Reviews (tollgate meetings) Supercharged DMAIC Crowdsourcing & Communities of Practice = The Power of the Collective Mind! Crowdsourcing & Communities of Practice = The Power of the Collective Mind! Utilize Idea Management Methods and Idea/Innovation Technology The Power of Trained Individuals and Teams in Lean, 6S or Lean Six Sigma Competencies Readily Attained Thru a Variety of Modalities 8. Rank key causes of waste and variation