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DMAIC project template
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6 sigma steps (DMAIC)
Define
Measure Analyze
Improve
Control
Define your business problem
Measure your process (Y) performance
Find the root causes (Xs) of the problem
Improve, implement new solution
Deliver Y performance over time
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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
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Why to do the project?
What if project not done?
Financial Business Case
Business Case
3 Business Case
What Comment Cost
K
Project Labor
Project Materials
Project Contractors
Equipment investment
Yearly operation cost
TOTAL Costs 0
Incremental RevenuesLabor Savings
Material Savings
TOTAL Benefits (1 year) 0
ROI 0
Define
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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
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7 (SIPOC)
Process map & CTQs
process as felt by the customer
Input Output
Supplier =My Company
Definition Specification Performancelimit targets
CTQ*
Step 2Step 1 Step 3
measurement
*Critical To Quality
My
Customer
Define
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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:DefinePerformancestandard
MeasureCTQ details
*LSL Lower Specification Limit*USL Upper Specification Limit
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M-step 3:
MeasurementSystemAnalysis
Measurement systemanalysis
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):
MeasureGage R&R
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M-step 4:
Baselinecurrent (As Is)processcapability
CTQ data collection planData sample size =Date of data collection:Where data have been collected?How data have been collected?
Will you take the opportunity to collect obvious Xs when collecting your CTQmeasurements?
If yes, which Xs:
Display an extract of the data collected:
MeasureCTQ data collection plan
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Continuous CTQSample 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 (m, median, Q1, Q3, other):Variability represented by its (s, 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:Baselinecurrent (As Is)processcapability
Photography of current performanceMeasure
Non NORMAL DistributionObserved DPMO=Equivalent ZLT=Equivalent ZST (ZLT+1.5)=
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Discrete CTQSample 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:Baselinecurrent (As Is)processcapability
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Continuous CTQNormal probability plot:
Conclusion (can we detect a true process and an unstable process?):
All type of CTQStability 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 processGraph Analysis
AnalyzeGraph analysis
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A-step 6:DefinePerformanceObjectives ofTo 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
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A-step 7:Identify Xs
(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:ExistAre applied
AnalyzeProcess analysis
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List of potential significant Xs
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 Low
Implementation
Easy
Hard
AnalyzePotential root causes
A-step 7:Identify Xs
(root causes)
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Results of segmentation (continuous CTQ only) :(Box plots, Scatter plots, Distributions per X)
Conclusion:
AnalyzeSegmentation analysis
A-step 7:Identify Xs
(root causes)
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Pareto chart of the CTQ categories:
Conclusion:
Pareto chart of the defect categories:
Conclusion:
FMEA:
Conclusion:
AnalyzePareto analysis
A-step 7:Identify Xs
(root causes)
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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 waysGLM
DOE screening
Conclusion/Prioritized list of significant Xs:
Financial benefits confirmation (Update your Business case):
AnalyzeHypothesis testing
A-step 7:Identify Xs
(root causes)
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I-step 8:Screen potentialcauses.List improvementactions/projects
List of Vital few Xs (screening DOE): Improvement action plan (Who What When):
ImproveImprovement actions
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I13
X tolerance settings:
I-step 9:DiscoverVariablerelationships(if necessary)
Transfer function:
Proposed Solution: Optimal Settings
Confirmation runs capability:
I-step 10:Establish
OperatingTolerances(if necessary)
ImproveImproved performance
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Project nameControlGage R&R on Xs
C-step 11:Define and
ValidateMeasurementSystem on Xs(if necessary)
Control on one X (yes/no):
If yes, X measurement systemanalysis:
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):
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C-step 12:Determine new
ProcessCapability
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 capabilityYield (%)=%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)=
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E bl t d it C i ht E bl Si Si C lti
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C-step 13:Implement
ProcessControl
Control Charts (SPC) in place/review mechanisms:
Mistake Proofing action taken:
FMEA control actions in place:
Process controlsControl
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