Roberto lopez

LSSMBB

Roberto.lopez@bomconsulting.net

DMAIC project template

6 sigma steps (DMAIC)

• Define

• Measure

• Analyze

• Improve

• Control

• Define your business problem

• Measure your process (Y) performance

• Find the root causes (X’s) of the problem

• Improve, implement new solution

• Deliver Y performance over time

Description of the problem (what? where? since when? based on which data?Based on which facts?)

Voice Of Customer (Customer perception)Internal perception

Competitors benchmark

1 Pb Statement

Business Problem

Develop Goal statement/opportunity or objective in clear, concise, measurable termsDemonstrate alignment of the project with the company/business strategy

2 Goal Statement

Define

Why to do the project?

What if project not done?

Financial Business Case

Business Case

3 Business Case

What Comment Cost

K€

Project LaborProject MaterialsProject ContractorsEquipment investmentYearly operation costTOTAL Costs 0Incremental RevenuesLabor SavingsMaterial SavingsTOTAL Benefits (1 year) 0

ROI 0

Define

Green Belt/Black Belt role:Team members/role:

Black Belt:Master Black Belt:VP Quality / Quality Manager:

Manager:Key stakeholders from Business team:

Customers:Others:

4 Project scope

Project: in scope

D M A I CDates:Gantt

Project: out of scope

Project charter

5 Team

6

Planning

Define

7 (SIPOC)

Process map & CTQ’s

process as felt by the customer

Input Output

Supplier =My Company

Definition Specification Performance limit targets

CTQ*

Step 2Step 1 Step 3

measurement

*Critical To Quality

My Customer

Define

M-step 1:Selected CTQs

Selected Project CTQ(s):

Discrete/continuous CTQ?

CTQ Operational Definition(s):

What is it (measurement starting point and end point) ?

How to measure it?

What is a defect?

If applicable to your CTQ, LSL* contractual value or limit defined by customer:

If applicable to your CTQ USL* contractual value or limit defined by customer:

M-step 2:Define Performance standard

MeasureCTQ details

*LSL Lower Specification Limit*USL Upper Specification Limit

M-step 3: Measurement System Analysis

Measurement system analysis

Data Collection plan for Repeatability & Reproductibility study:Data sample size =Date of data collection:Where data have been collected?How data have been collected?How many operators? How many repeats per operator?

Gage R&R study – Continuous data:

-Tolerance (USL-LSL):

-Short method (yes/no):

-Gage R&R as %contribution: Gage R&R as %tolerance: Nb of distinct categories:

Gage R&R study – discrete data:If we have a Known sample (a reference), then how was built the known sample?

Conclusion/decision taken (evidence that the measurement of our CTQ is reliable):

MeasureGauge R&R

M-step 4: Baseline current (As Is) process capability

CTQ data collection plan•Data sample size =•Date of data collection:•Where data have been collected?•How data have been collected?

•Will you take the opportunity to collect obvious X’s when collecting your CTQ measurements?

•If yes, which X’s:

•Display an extract of the data collected:

MeasureCTQ data collection plan

Continuous CTQ•Sample size=•Short term data or Long term data?•Histogram with Normality test result and descriptive statistics:

•Type of the distribution (normal, other):•Trend represented by its (, median, Q1, Q3, other):

•Variability represented by its (P95, Q1/Q3, other):

PROCESS CAPABILITY MEASURE:NORMAL DistributionObserved DPMO=Potential DPMO=ZLT =ZST (ZLT+1.5)=

Conclusion•Problem with trend, variability or both?

M-step 4: Baseline current (As Is) process capability

Photography of current performanceMeasure

Non NORMAL DistributionObserved DPMO=Equivalent ZLT=Equivalent ZST (ZLT+1.5)=

Discrete CTQ•Sample size: •Short term data or Long term data?•Process capability

•Yield (%)=•%defects=•DPMO=•Opportunities per unit=•DPU=•Equivalent ZLT=

•Equivalent ZST (ZLT+1.5)=•95% confidence interval on DPMO:

MeasurePhotography of current performance

M-step 4: Baseline current (As Is) process capability

Continuous CTQ•Normal probability plot:

Conclusion (can we detect a true process and an unstable process?):

All type of CTQ•Stability over time/Run chart:

Conclusion:•Pb of technology (short term common causes)?•Pb of control (long term shift due to special causes)?•Both pbs?

A-step 5:As Is process Graph Analysis

AnalyzeGraph analysis

A-step 6: Define Performance Objectives of To Be process

Improvement GoalTarget (from benchmark) for:

Trend:Variability:LT DPMO or LT %defects=Yield (%)=ZLT=ZST=(ZLT+1.5)=

Gap (Improvement – Actual)DPMO gap or Defect reduction factor:Z gap=

6 Sigma tools necessary to meet performance objectives:• Ground fruit: Logic and Intuition• Low hanging fruit: Basic tools (Process Map, CE/CNX fishbone diagram, SOP, FMEA, Pareto, Histogram, Box plot)• Bulk of Fruit Process Characterization and Optimization• Sweet Fruit: Transform the project into a DFSS project

AnalyzeSet expected performance

A-step 7: Identify X’s (root causes)

Process (AS IS) detail analysis:•Detailed process map

Conclusion

•CTQ Intermediate distribution plot (continuous CTQ only)

Conclusion

Standard Operation Procedures analysis:•Exist:•Are applied:•Incitation to apply them exist:•Training has been given to operators:

Policy analysis:•Exist•Are applied

AnalyzeProcess analysis

List of potential significant X’s

Y/CTQ Output

Men

Machines

Materials

Methods

Measurements

Environment

Fishbone diagram of my Y

Label C/N/X on your fishbone, then rate every X impact vs implementation (table below)

1 2

3 4

Impact

High LowImplementation

Easy

Hard

AnalyzePotential root causes

A-step 7: Identify X’s (root causes)

Results of segmentation (continuous CTQ only) :(Box plots, Scatter plots, Distributions per X)

Conclusion:

AnalyzeSegmentation analysis

A-step 7: Identify X’s (root causes)

Pareto chart of the CTQ categories:

Conclusion:

Pareto chart of the defect categories:

Conclusion:

FMEA:

Conclusion:

AnalyzePareto analysis

A-step 7: Identify X’s (root causes)

Statistical Tests PerformedTest X Factors p value %contribution conclusion

one sample or two sample T-testAnnova one wayHomogeneity of varianceChi square testSimple regressionNon parametric data testANOVA 2 waysGLMDOE screening

Conclusion/Prioritized list of significant X’s:

Financial benefits confirmation (Update your Business case):

AnalyzeHypothesis testing

A-step 7: Identify X’s (root causes)

I-step 8:Screen potential causes.List improvement actions/projects

List of Vital few Xs (screening DOE): Improvement action plan (Who What When):

ImproveImprovement actions

I13

X tolerance settings:

I-step 9: Discover Variable relationships(if necessary)

Transfer function:

Proposed Solution: Optimal Settings

Confirmation runs capability:

I-step 10: Establish Operating Tolerances(if necessary)

ImproveImproved performance

ControlGage R&R on X’s

C-step 11:Define and Validate Measurement System on X’s(if necessary)

Control on one X (yes/no):

If yes, X measurement system analysis:

•Data Collection plan for Repeatability & Reproductibility study:Data sample size =Date of data collection:Where data have been collected?How data have been collected?How many operators? How many repeats per operator?

•Gage R&R study – Continuous data:

-Tolerance (USL-LSL):

-Short method (yes/no):

-Gage R&R as %contribution: Gage R&R as %tolerance: Nb of distinct categories:

•Gage R&R study – discrete data:If we have a Known sample (a reference), then how was built the known sample?

•Conclusion/decision taken (evidence that the measurement of our X is reliable):

C-step 12: Determine new Process Capability

Process or Product new capability:

Continuous CTQ:NORMAL DistributionObserved DPMO=Potential DPMO=ZLT =ZST (ZLT+1.5)=

Discrete CTQ:•Sample size:=•Short term data or Long term data?•Process capability•Yield (%)=•%defects=•DPMO=•Opportunities per unit=•DPU=•Equivalent ZLT=•Equivalent ZST (ZLT+1.5)=•95% confidence interval on DPMO

Statistical Confirmation of Improvement (by statistical test):

Confirmation of improved performanceControl

Non NORMAL DistributionObserved DPMO=Equivalent ZLT=Equivalent ZST (ZLT+1.5)=

C-step 13: Implement Process Control

Control Charts (SPC) in place/review mechanisms:

Mistake Proofing action taken:

FMEA control actions in place:

Process controlsControl