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DMAIC Components
- 2. D1. Map Project D2.Approve Project M1. CTQ Characteristics& Standards M2. Measurement System Analysis M3. Data Collection A1. Baseline Process A2. Performance Objective A3. Identify Drivers of Variation I1. Screen for Vital Xs I2. Screen for vital Xs I3. Define Improved Process C1. MSA on Xs C2. Improved Process Capability C3. Establish Control Plan Key Deliverables: • List of Customer(s) and Project CTQs • Team Charter • High Level Process Map (COPIS) • CAP Plan (Optional) • Preliminary CBA, if applicable • QFD / CTQ Tree • Operational definition, Specification limits, target, defect definition for Project Y(s) • Data Collection Plan • Measurement System Analysis • Baseline of Current Process Performance • Normality Test • Statistical Goal Statement for Project • List of Statistically Significant Xs • List of Vital Few Xs • Transfer Function(s) • Optimal Settings for Xs • Confirmation Runs/Results • Tolerances on Vital Few Xs • MSA Results on Xs • Post Improvement Capability • Statistical Confirmation of Improvements • Process Control Plan • Process Owner Signoff • Final CBA, if applicable Tollgates: Planned Completed 10/June/2010 11/March/2010 mm/dd/yyyy mm/dd/yyyy mm/dd/yyyy XXXXXX 15/March/2010 mm/dd/yyyy mm/dd/yyyy mm/dd/yyyy Steps: Tools: Survey Focus Groups Interviews ARMI, Stakeholder Analysis In/Out of Frame Threat vs. Opportunity Matrix Other ______________ Data Collection Plan Continuous Gage R&R Attribute Gage R&R Sample Size Calculator Other ______________ Basic Statistics Histogram Dot Plots Box and Whisker Plots Run Charts Normality Testing Continuous/Discrete Zst, Zlt Benchmarking Detailed Process Mapping Moments of Truth Nature of Work Flow of Work Fishbone Hypothesis Testing Regression Analysis Other ______________ DOE Pugh Matrix New Process Mapping FMEA on new process Process Modeling / Simulation Other ______________ Continuous Gauge R&R Discrete Gauge R&R Control Charts Hypothesis Testing CAP Plan Control Plan Other ______________ Define Measure Analyze Improve Control OVERVIEW Project Progress Tracking
- 3. Define Deliverables DEFINE SIPOC Process Map CommunicationPlan ARMI/RASIC Terms & Acronyms Used Project Charter Map the Project
- 4. Project Mapping DEFINE Customer SampleComments Key Output Characteristics Important to Customer (CTQ's)
- 5. Project Charter Business CaseIn Scope Out Scope Problem Statement Goal Statement Target Date Actual Date Start Date Define Measure Analyze Improve Control High Level Project Plan DEFINE
- 6. Terms & AcronymsUsed DEFINE Indicators Definition
- 7. ARMI DEFINE Key Stakeholders DefineMeasure Analyze Improve Control When Populating the Stakeholder, consider the ARMI: • A= Approver of team decisions • R= Resource or subject matter expert (ad hoc) • M= Member of team • I= Interested Party who will need to be kept informed
- 8. Communication Plan DEFINE Message AudienceMedia Who When
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- 10. COPIS DEFINE Customer Output ProcessInput Supplier
- 11. Measure Deliverables MEASURE Process Capability MeasurementSystem Analysis (MSA) Data Collection Plan
- 12. Data Collection Plan MEASURE Y Operational Definition DefectDefinition Performance Standard Specification Limit Opportunity Y Data Type Unit of Measurement Decimal Places Database Container Existing/New Database If new, when would the database be ready Planned Start date for Data Collection Equipment Used for Measurement Equipment Calibration Info Responsibility Training Need Operation Details Mode of Collecting Data
- 13. Measurement System Analysis MEASURE MinitabDescriptive Statistics Rule Rule Description Acceptable Result A R&R % of Tolerance < 10% B % Contribution (R&R Std deviation) Smaller than Part to Part Variation C Number of distinct categories >=4 Overall Gage Result
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- 15. Analyze Deliverables ANALYZE MSA resultsof Impacting Factors Hypothesis Summary Checking for Impact of Xs on Y Basic Analysis for Project Y DCP for Potential Xs Fishbone Identify Potential Xs
- 16. Cause & EffectDiagram ANALYZE
- 17. DCP for PotentialXs ANALYZE Potential Cause Type of Data Collection Method Test to be Used Visualization plot Used Outlining Data Collection Steps for Xs
- 18. Basic Data Analysisfor Project Y ANALYZE Randomness Study Randomness & Shape Study Normality Study
- 19. Basic Data Analysisfor Project Y ANALYZE Spread Study Spread & Central Tendency Study Central Tendency Study
- 20. Checking for Impactof x1 on Y ANALYZE Graphical Depiction Statistical Interpretation of Relationship Hypothesis Result Inference:
- 21. Checking for Impactof x2 on Y ANALYZE Graphical Depiction Statistical Interpretation of Relationship Hypothesis Result Inference:
- 22. Checking for Impactof x3 on Y ANALYZE Graphical Depiction Statistical Interpretation of Relationship Hypothesis Result Inference:
- 23. Checking for Impactof x4 on Y ANALYZE Graphical Depiction Statistical Interpretation of Relationship Hypothesis Result Inference:
- 24. Checking for Impactof x5 on Y ANALYZE Graphical Depiction Statistical Interpretation of Relationship Hypothesis Result Inference:
- 25. Hypothesis Summary ANALYZE Summary ofImpacting Factors S. No. Factor p – Value Graphical Tool Used Inference Next Steps
- 26. MSA Results ofImpacting Factors ANALYZE Checking the validity of data of the Impacting Factors S. No. Factor MSA Method Used MSA Result RCA for Problems Next Steps
- 27. Improve Deliverables IMPROVE Improve Summary– Take Aways Pre-Post Analysis of Factor Pre–Post Analysis of Project Y Basic Analysis of Improved Y Action Plan for Improving the Factors Screening of the Impacting Factors
- 28. Screening of ImpactingFactors IMPROVE Prioritize the Impacting Factors
- 29. Action Plan forImproving the Factors IMPROVE S. No. Pain Area Root Cause Improvement Idea Implementation Owner Implementation Status
- 30. IMPROVE Randomness Study Randomness &Shape Study Normality Study Basic Data Analysis of Improved Y
- 31. IMPROVE Spread Study Spread &Central Tendency Study Central Tendency Study Basic Data Analysis of Improved Y
- 32. Pre – PostAnalysis of Project Y IMPROVE Graphical Depiction Statistical Validation of Improvement Hypothesis Result Inference:
- 33. Pre – PostAnalysis of Project Y IMPROVE Graphical Depiction Statistical Validation of Improvement Hypothesis Result Inference:
- 34. Pre – PostAnalysis of Factor IMPROVE Graphical Depiction Statistical Validation of Improvement Hypothesis Result Inference:
- 35. Pre – PostAnalysis of Factor IMPROVE Graphical Depiction Statistical Validation of Improvement Hypothesis Result Inference:
- 36. Pre – PostAnalysis of Factor IMPROVE Graphical Depiction Statistical Validation of Improvement Hypothesis Result Inference:
- 37. Pre – PostAnalysis of Factor IMPROVE Graphical Depiction Statistical Validation of Improvement Hypothesis Result Inference:
- 38. Pre – PostAnalysis of Factor IMPROVE Graphical Depiction Statistical Validation of Improvement Hypothesis Result Inference:
- 39. Improve Summary –Take Away IMPROVE
- 40. Control Deliverables CONTROL Cost BenefitAnalysis and Sign Off Control Charts & Inference (for X2) Control Charts & Inference (for X1) Establish Process Capability Basic Analysis of Improved Y Control Charts & Inference for Y – Pre & Post Time Series Study of Y – Pre & Post Control Plan & FMEA on Control Plan
- 41. Control Plan &FMEA on Control Plan CONTROL What’s Controlled Goal/Spec Limits Control Method Who/What Measures Where Recorded Decision Rule / Corrective Action SOP
- 42. Time Series Studyof Y – Pre & Post CONTROL
- 43. Control Charts &Inference for Y – Pre & Post CONTROL
- 44. CONTROL Randomness Study Randomness &Shape Study Normality Study Basic Data Analysis of Controlled Y
- 45. CONTROL Spread Study Spread &Central Tendency Study Central Tendency Study Basic Data Analysis of Controlled Y
- 46. Establish Process Capability CONTROL ProcessCapability – Post Implementation Z Bench (Long Term Sigma) Short Term Sigma (Long Term Sigma + 1.5)
- 47. Control Charts &Inference (x1) CONTROL
- 48. Control Charts &Inference (x2) CONTROL
- 49. Cost Benefit Analysis& Sign Off CONTROL Benefit Source Unit Benefit Units Impacted Total Benefit Cost Reduction Enhanced Revenues Labor Reduction Decreased Overhead COPQ Reduction
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- 51. Stakeholder Analysis Want tosee More Of Want to see Less Of
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- 53. RASIC CONTROL RASIC Chart forDefine & Measure Activities Team Members Pre- DMAIC Collect VOC from all stakeholders Conduct Stakeholder analysis Collect data for the last 12 months Analysis of data Report out on the Pre DMAIC Analysis DEFINE Create Project Charter Send Charter for Executive Approval Approve Charter Build SIPOC Build Process Map MEASURE Build the data collection plan Get the DCP Approved Approve DCP Collect Data Validate data Publish next steps to stakeholder • Responsible (R) : Solely and directly responsible for the activity (Owner) - Includes approving authority (A) • Approve (A) : Reviews and assures that the activity is being done as per expectations • Support (S) : Provides the necessary help and support to the owner • Inform (I) : Is to be kept informed of the status/progress being made • Consult (C) : Is to be consulted for this activity for inputs
- 54. Advance Innovation Group www.advanceinnovationgroup.com E-26,Sector 8 Noida, UP – 201301 India Advance Innovation Group 3 continents. One team. AIG is headquartered in Boston, Massachusetts and maintains several consulting and training delivery centers across Asia Pacific including India. Asia Pacific operations is headquartered at Noida, India with several offices and training facilities. Global offices allow us closer client contact to better serve your needs, while enriching our services with global perspective and experience.