Module-2

DMAIC – Process Improvement

 DMAIC Improvement Process

Define

Measure
Identify
Opportunity Analyse
Identify
Output Improve
Measures
(y’s) Identify
Critical Inputs
Control
Or Process Optimise
Steps The
(x’s) Process Control
The
Process
 Six Sigma Improvement Process
Define Measure Analyse Improve Control

Select Project
Define Measures (y’s)
Develop Detailed
Brainstorm Potential
Control Critical x’s

Define Project Process Maps Improvement Strategies
10.2 Upper Control Limit
START
Select Improvement
Objective
PROCESS Strategy 10.0

Form the Team
Check Data Integrity STEPS

9.8 Lower Control Limit

DECISION Criteria A B C D 9.6

1 5 10 15 20
Time + s - +
STOP
Cost + - + s
Monitor y’s
Service - + - +

Identify Critical Etc s s - +
Process Steps (x’s)

Determine Process by looking for:

Map the Process Stability
Plan and Implement
– Process Bottlenecks y

Identify Customer
Determine Process
Pilot
Requirements Capability – Rework / Repetition
Verify Improvement
Validate Control
– Non-value Added Plan
Steps LSL USL
LSL USL
– Sources of Error /
Mistake

Map the Ideal 15 20 25 30 35
15 20 25 30 35 Process
Identify further

Identify Priorities
Implement opportunities
Set Targets for
Identify gaps

Countermeasures
Close Project

Update Project File between current and
Measures
ideal

Phase Review Phase Review Phase Review Phase Review Phase Review
 DMAIC
Define Phase Flowchart
Identify Opportunity& Clarify with Sponsor

Define Project Objective

Form the Team

Map the Process

Identify Customer Requirements

Identify Priorities

Complete Project Definition

Review Project with Sponsor

 DMAIC - Define Useful Tools
Define Measure Analyse Improve Control

Project Database Minitab Software

D e s c rip tiv e S ta tistic s
Process
Project V a r ia b le : S A T
Map
Charter An d e r s o n -D a r lin g N o rm a lity T e s t
A- S q u a re d :
P -V a lu e :

M ean
0 .3 2 9
0 .5 1 2

5 9 0 .2 4 0
e.g.
S tD e v 6 5 .1 0 1

SIPOC
Va r ia n c e 4 2 3 8 .0 8
S ke w n e s s 2 .6 3 E -0 2
K u rto s is - 4 .0 E -0 1
N 100
44 0 500 56 0 620 6 80 7 40
M in im u m 4 2 6 .0 0 0
1 s t Q u a rtile 5 4 2 .2 5 0
M e d ia n 5 9 8 .0 0 0
3 rd Q u a r tile 6 4 0 .0 0 0
9 5 % C o n fid e n c e In te rv a l fo r M u M a xim u m 7 4 0 .0 0 0
9 5 % C o n fid e n c e In te rv a l fo r M u
5 7 7 .3 2 3 6 0 3 .1 5 7
56 8 57 8 588 59 8 6 08 9 5 % C o n fid e n c e In te r v a l fo r S ig m a
5 7 .1 5 9 7 5 .6 2 6
9 5 % C o n f id e n c e In te r v a l fo r M e d ia n
9 5 % C o n fid e n c e In te rv a l fo r M e d ia n
5 7 0 .7 1 1 6 0 5 .0 0 0

Customer
Focus Review
Rolled Templates
Throughput Pareto
D Control Charts
Yield M
A x x
x x x x
0.82 0.99 0.75 I x x
C x
x
 DMAIC - Measure Phase Flowchart
Do y’s Reflect Yes Is Data No Improve
Define
Customer Check Data Integrity Generated Measurement
Measures (y’s)
Requirements? Consistently? System

Yes
Review No
Project
Variable Attribute
Collect Attribute or
Data Variable
Check 7 Reasons Binomial Poisson
Data
Draw Histogram Type?
Yes
New Sample Collect Collect
Required? Data Data
No Yes
Is Data Create
No Normal? I/MR Chart
Create Create
Yes
Is Data P Chart u Chart
Normal?
No Is Process Binomial Poisson
Stable? Capability Capability
Create Run Chart Yes
No

Calculate % Yield Process Capability Process Capability

% Yield Dpu, % Yield
Estimate Ppk Cpk, Ppk, Yield Ppk, Yield

Determine Improvement
Approach

Go to Analyse Phase Go to Analyse Phase Go to Analyse Phase Go to Analyse Phase

(Stability Issue) (Targetting Average Issue) (Targetting Variation Issue) (Mistake Proofing Issue)
 DMAIC – Measure Useful Tools
Define Measure Analyse Improve Control

Customer Project Database Histogram

Focus Process
Map
e.g.
SIPOC

Review Templates
Pareto
D
M
A
I
C Drill Down

Control Charts Y
Process Minitab Software
Capability D e s c rip tiv e S ta tis tic s
V a ri a b le : S A T

A n d e r s o n -D a r lin g N o r m a l ity T e s t
x
A-S qu a re d :
P -V a l u e :

M ea n
0 .3 2 9
0 .5 1 2

5 9 0 .2 4 0
x x
x x x y y y
S tD e v 6 5 .1 0 1
V a r ia n c e 4 2 3 8 .0 8
S ke w n e ss 2 .6 3 E - 0 2

44 0 50 0 5 60 620 680 74 0
K u rt o s is
N

M in im u m
1 s t Q u a r t ile
- 4 .0 E - 0 1
100

4 2 6 .0 0 0
5 4 2 .2 5 0 x x
9 5 % C o n fi d e n c e In t e rv a l f o r M u
M e d ia n
3 r d Q u a r tile
M a x im u m
5 9 8 .0 0 0
6 4 0 .0 0 0
7 4 0 .0 0 0 x
x
9 5 % C o n f id e n c e In t e rv a l f o r M u
5 7 7 .3 2 3 6 0 3 .1 5 7
5 68 57 8 58 8 59 8 60 8 9 5 % C o n fid e n c e In te r v a l fo r S ig m a
5 7.1 5 9 7 5 .6 2 6
9 5 % C o n f id e n c e In t e rv a l fo r M e d ia n
9 5 % C o n f id e n c e In t e rv a l fo r M e d ia n
5 7 0 .7 1 1 6 0 5 .0 0 0
 DMAIC
Analyse Phase Flowchart
Stability Targetting Average Targetting Variation Mistake Proofing
Issue Issue Reduction Issue Issue

Develop Detailed Process Maps

Identify Waste and Sources of Variation

using 7 Wastes, VA/NVA, Costs

Develop the Ideal

Process Maps

Perform a Gap Analysis

Identify Critical x’s

(Process steps or inputs)

Review Project
Critical X’s
with Sponsor
 DMAIC - Analyse Useful Tools
Define Measure Analyse Improve Control

Review Templates
Cause & Effect Scatter Minitab Software
D Diagram D escriptive Statistics Process
Diagram
M x
V ariable : SA T

x x Anderson-Darling Normality T est

A-Squared: 0.329
Map
A
P-Value: 0.512

Man Machine x x Mean 590.240

e.g.
x
StDev 65.101

x
Variance 4238.08
Skewness 2.63E-02

I xx
Kurtosis -4.0E-01

SIPOC
N 100
440 500 560 620 680 740

x x
Minimum 426.000
1st Quartile 542.250

Effect C x 95% Confidence Interval for Mu

Median
3rd Q uartile
Maximum
598.000
640.000
740.000
95% Confidence Interval for Mu
577.323 603.157
568 5 78 5 88 59 8 60 8 95% Confidence Interval for Sigma
57.159 75.626
95% Confidence Interval for Median
95% Confidence Interval for M edian
570.711 605.000

Maint. Method Histogram

Project Database

Seven Wastes
Regression FMEA
Analysis Overproduction

y y=f(x) Bulb Tr ts
M
ot ans Defec
blown ion p ort
ati
Inv on
Room OR No Power OR en
t or

O
Dark y

ve

W ess
rp
Switch

ai
ro

tin ng
c
failed

g
i
Fault Tree Analysis,FTA
x
 DMAIC
Improve Phase Flowchart
Brainstorm
Improvement Strategies

Select
Improvement Strategy

Plan & Implement

Pilot Study

Verify Process
Capability

No
Pilot Study Implement
Successful? Countermeasures

Yes
Review with Sponsor
& go to Control Phase
 DMAIC - Improve Useful Tools
Define Measure Analyse Improve Control

Concept Selection Minitab Software FMEA

Matrix D e sc rip tive S tatistics
V a ria b le : S A T

An de rs on -D a rlin g N o rm a lity T es t
A-S qu a re d: 0 .3 2 9
P - Valu e: 0 .5 1 2

Criteria A B C D Mean
S tD e v
Va ria n c e
S k ew n e s s
5 90 .2 4 0
65 .1 0 1
4 23 8 .0 8
2 .63 E -0 2
K u rto s is -4 .0 E -0 1

Time + s - + 44 0 500 56 0 620 6 80 740

N

M in im u m
1 s t Q u ar tile
100

4 26 .0 0 0
5 42 .2 5 0
M e d ia n 5 98 .0 0 0

Cost + - + s 9 5 % C o n fid e nc e Inte rv al for M u

3 rd Q ua rtile
M a xim u m
6 40 .0 0 0
7 40 .0 0 0
9 5 % C o n fid e nc e Inte rv al fo r M u
5 77 .3 23 6 03 .1 5 7

Service - + - + 56 8 5 78 588 598 608 95 % C o nfide n c e In te rv a l fo r S ig m a

57 .1 59 75 .6 2 6
9 5% C o nfide n c e In te rv a l fo r M ed ian
9 5% C o nfid en c e In te rv a l fo r M ed ian
5 70 .7 11 6 05 .0 0 0

Etc s s - +
Review Templates
Project Database
Mistake D
Proofing M
A
I
C Process
Map
Bulb
e.g.
Process
blown SIPOC
Capability
Room OR No Power OR
Dark
Switch
failed
Fault Tree Analysis,FTA
DMAIC - Control Phase Flowchart

Control Critical x’s

• Establish Control Plan
• Develop/Update FMEA
• Update Quality System

Monitor y’s

Validate Control Plan

No
Is Control Plan Review
Validated? Project

Yes

Finalise
Project Report
 DMAIC - Control Useful Tools
Define Measure Analyse Improve Control

Review Minitab Software Project Database

Templates D escriptive Statistics
Process
D
Variable: SAT

Anderson-Darling Normality T est

Map
M
A-Squared:
P-Value:

Mean
StDev
0.329
0.512

590.240
65.101
e.g.
SIPOC
Varianc e 4238.08
Skew ness 2.63E-02

A
Kurtos is -4.0E-01
N 100
440 500 560 620 680 740
Minimum 426.000
1st Quartile 542.250

I
Median 598.000
3rd Q uartile 640.000
95% Confidence Interval for M u Maximum 740.000
95% C onfidenc e Interval for M u
577.323 603.157

C 568 578 5 88 5 98

95% Confidence Interv al for Median

6 08 95% Confidenc e Interval for Sigma
57.159 75.626
95% C onfidence Interval for M edian
570.711 605.000

FMEA
Control Charts
Process
Capability x Mistake
x
x
x x x Proofing
x x
x
x