The Process DMAIC

1
The Process DMAIC

• Lean Foundations
• Continuous Improvement Training

2
Key Learning Points

• Problem Solving is a
• Process Process Process

3
The Process DMAIC
Define

• CHARTER
• Problem Goal Statement
• Milestones
• Resources Allocation
• Roles definition
• Benefits Model

• HP (Hoshin Planning)
• COPQ
• 7W /6S
• Project scope
• Desirability Matrix
• Primary metric
• Secondary metric
• Brown Paper

• 6-S(5S safety)

4
The Process DMAIC
Establish Process Capability
Understand variation

• Voice of the customer
• Process Sigma
• Other Capability measures
• BASELINE

• Data Definition
• Types of data
• Data collection
• Takt time
• Time Observation sheets

• MSA
• Common cause
• Special cause
• Graphical display
• Run Charts
• Control charts

• SIPOC
• Value Added
• Non Value Added
• Cycle time
• Process time
• Defects
• Brown Paper

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The Process DMAIC

• Identify Critical Xs
• Y f (X)
• Recalibrate Scope
• Establish targets

• Process map analysis (VA/ NVA)
• Advanced analytical tools

• Pareto
• Cause Effect Diagram
• Scatter diagram
• Spaghetti Diagram
• XY matrix
• FMEA
• Cycle time/Takt time

6
The Process DMAIC
Select Solutions
Generate Solutions

• Brainstorming
• Benchmarking
• DOE

• Impact Grid matrix
• N/3
• Cost Benefit Analysis
• Voting
• DOE

• PLANNING
• FMEA
• Pilot
• Leading Change Strategy
• Kaizen
• Poka-Yoke

7
The Process DMAIC
Standardize Document

• FMEA
• Control Plan
• Process behavior chart

• Project storyboard
• Project report Projects database
• Closure Checklist
• Project hand-over

• Standards
• Procedures
• HP
• Audits
• Systems Structures

• Measurement system
• Control Charts
• Run charts

8
In Short

• Define the problem and objective
• Collect data and ensure it is factual
• Identify the root cause of the problem
• Develop changes, test, validate and implement
  solutions
• Control and sustain the improvement

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The Process DMAIC

• This is just
• THE BEGINNING!

10
The Process DMAIC

• Lean Foundations
• Continuous Improvement Training