ASQ Raleigh ASQ Raleigh Section 1113 Six Sigma SIG DMAIC Series
To solve problems and to avoid the re-occurrences of these problems a structured and data-based method, called DMAIC, is used. Define customer expectations of the process Measure the frequency of defects Analyze why, when and where the defects occur Improve process operation by eliminating waste and variation Control the process so it stays fixed and sustainable D M A I C
DMAIC Flowchart: Method of Improving Exiting Processes
DMAIC: Define Define – What is important? Scope and boundary Define defects Team charter and champion Estimated project impact Leadership approval
DMAIC: Define Objectives To identify or validate the improvement opportunity. To develop the business processes, define critical customer requirements, and prepare to be an effective project team. Main Activities Validate/Identify business opportunity Identify stakeholders Identify team members Develop team charter Identify and map process Identify quick wins Develop team guidelines and ground rules Define project Y’s
DMAIC: Measure Measure – How are we doing? Map process and identify inputs and outputs Cause and effect matrix Establish measurement system capability Establish process capability baseline
DMAIC: Measure Objectives To identify critical measures that are necessary customer requirements and begin developing a method for effectively collecting data to measure process performance. To understand the elements of Six Sigma calculation and establish baseline sigma for the process in question Main Activities Identify input, process, and output indicators Develop operational definition and measurement plan Plot and analyze data Determine if special cause exists Cause and effect matrix Collect other baseline performance data Failure modes and effect analysis
DMAIC: Analyze Analyze – What is wrong? Complete FMEA Perform multivariate analysis Identify potential critical inputs Develop plan for next phase
DMAIC: Analyze Objectives To identify and validate the root causes that create the problem the team is focused on. To determine true sources of variation and potential failure modes that lead to customer dissatisfaction. Main Activities Stratify process Stratify data & identify specific problem Develop problem statement Identify root causes Design root cause verification analysis Validate root causes Comparative analysis Sources of variation analysis Regression analysis Process control Process capability Design of experiments
DMAIC: Improve Improve – What needs to be done? Verify critical inputs Optimize critical inputs
DMAIC: Improve Objectives To identify, evaluate, and select the right improvement solutions. To develop a change management approach to assist the organization in adapting to the changes introduced through solution implementation. Main Activities Design of experiments Response surface methods Generate solution ideas Determine solution impacts: benefits Evaluate and select solutions Develop process maps & high level plan Develop and present storyboard Communicate solutions to all stakeholders Develop pilot plan & pilot solution
DMAIC: Control Control – How do we guarantee performance? Implement control plan Verify long term capability Continuously improve process
DMAIC: Control Objectives To understand the importance of planning and executing against the plan and determine the approach to be taken to assure achievement of the targeted results. To understand how to disseminate lessons learned, identify replication and standardization opportunities/processes, and develop related plans. Main Activities Verify that reduction in root cause sigma resulted from solution Identify whether additional solutions are necessary to achieve goal Identify and develop replication and standardization opportunities Integrate and manage solutions in daily work processes Integrate lessons learned Identify teams next steps and plans for remaining opportunities