MODULE 2. DMAIC PROCESS.

The six Sigma methodology uses Project management approach to execute tasks,
called. Define-Measure-Analyze-Improve-Control.
DMAIC. Provides the structure to successfully solve process problems, in existing
processes, once and for all.

Topic 2.1. Definition Phase.

Define opportunities.
Objectives.
 Identify and/or validate the business improvement.
 Define critical customer requirements.
 Document (map) processes.
 Establish project charter, build team.
 Define a vision and project strategy to achieve the vision.
 Review your design charter.
 Opportunity, goal, scope.
 Validate by leadership.
 Identify initial design requirements based on “Voice of customer”.
 Document the process where design will focus.
In the define phase of DMAIC there are three key elements that we seek to
understand.
1. Clarify the business problem.
2. Identify and validate customer requirements.
3. Begin documentation of the process.
Tools.
 SIPOIC is a tool that documents a process from supplier to customers. Once
completed, it is used to.
 Identify and balance competing customer requirements.
 Aid in identification of data collection needs.
 See process connected to the customer.
 Avoids getting stuck in details.
 A simplified view of entire process visible at glance.
 Help provide scoping direction on projects.
 Process Map. Graphical representation of a process.
 Identifies key process input variables (KPIV’s, also called little x’s)
 Identifies key process outputs variables (KPOV’s also called little y’s)
Output.
 Project Charter.
 Problem statement.
 Goal statement.
 In/Out of scope.
 Team and time commitments.
 Timeline / Milestone.
 Estimate financial benefit.
 Risks, constrains and compliance issues identified.
 SIPOIC or high level process map

Topic 2.2. Measurement Phase.

Measure performance. Reliable data is needed to answer questions and make good
decisions.
Objectives.
 Determine what to measure.
 Manage measurement data collection.
 Develop and validate measurement system.
 Determine sigma performance level
When developing a data collection plan ensure that:
1. The data collected are meaningful.
2. The data collected are valid.
3. All relevant data is collected at same time.
Tools.
 Knowledge-Based tools.
 Process flow chart.
 Cross-Functional flow chart.
 Work flow (spaghetti) diagram.
 Value stream map.
 Cause and effect diagram.
 Prioritization matrix.
 Cause and effect matrix.
 5 Why’s.
 Data-Based tools.
 Operational definition.
 Data collection plans.
 Required sample sizes for α, β, δ and σ.
 Surveys.
  Measurement plan.
 Performance measures.
 Process stability.
 Process capability
Output.
 Detailed process maps.
 Input, process and outputs indicators.
 Operational definitions.
 Data collection plan.
 Measurement system analysis.
 Baseline performance / Process capability.

Topic 2.3. Analysis Phase.

Analyze opportunity.
Objectives.
 Analyze data to understand reasons for variation and identify potential root
causes.
 Determine process capability, throughput and cycle time.
 Formulate investigate, and verify root cause hypothesis.
How can we obtain data for analysis?
1. A retrospective study using historical data.
2. An observational study.
3. A designed experiment.
Tools.
 Identify potential root causes.
 Cause and effect diagram.
 Cause and effect matrix.
 5 Why’s.
 FMEA.
 Histogram.
 Scatter plot and correlation.
 Box plots.
 Pareto diagram.
 Run chart.
 Control chart.
 Value-Add analysis.
 Validate potential root causes.
 Hypothesis testing.
  One the standard (One Sample)
 One to one (Two sample)
 Multiple comparison (ANOVA)
 Nonparametric methods.
 Categorical methods.
 Regression analysis.
 Screening experiments.
Output.
 Data analyses.
 Validation root causes.
 Sources of variations.
 Process FMEA.
 Potential solution.

Topic 2.4. Improvement Phase.

Improve performance.
Objectives.
 Generate and quantify potential solutions.
 Evaluate and select final solution.
 Verify and gain approval for final solution.
 Manage change.
In the improve phase we need to identify potential solutions.
Tools.
 Best practices.
 Replication and standardization arising from other projects.
 Benchmarks.
 Brainstorming/Affinity diagram.
 Designed experiments.
 Lean specific approaches.
 Mistake proofing, 5S’s, Visual workplace.
 Kaizen,
 Process balancing.
 Rapid Set-Up (SMED)
 TPM
 Cost/Benefit analysis.
 Preference testing.
 Solution selection matrix.
 Pugh matrix.
 Pay-off priority matrix.
  Simulation.
 Limited pilot.
Output.
 Final solution.
 Estimated improvement impact.
 Cost/Benefit analysis.
 Piloted solution with confirmed results.
 Updated process maps and documentation.
 Full-Scale implementation plan.

Topic 2.5. Control Phase

Control performance.
Objectives.
 Implement solution.
 Develop plan to maintain gains.
 Identify replication and standardization opportunities.
 Closure activities.
Tools.
 FMEA updated with actions taken.
 Process control plan.
 Measurement system control plan.
 Integration with work systems.
 Standards and procedure.
 Training.
 Process performance metrics.
 Management performance reviews.
Output.
 Process control plan.
 Verified solution results.
 Opportunities for replication and standardization.