Six Sigma:

DMAIC
OPS/571
Operations Management
Six Sigma: DMAIC

Objectives of DMAIC
• Understand the process
• Eliminate errors
• Remove slack
• Reduce variation
• Plan for continual improvement

DMAIC
Define Measure Analyze Improve Control
Opportunities Performance Opportunity Performance Performance
Define:
Define Opportunities
Six Sigma: DMAIC

Define
Measure Analyze Improve Control
Opportunities Performance Opportunity Performance Performance

Objective Main Activities Tools/Techniques Key Deliverables

Control Chart
• Identify • CCR • Define opportunities &
Assessment
improvement measurable goals
opportunity • Employee
responsibility • Critical Customer
• Develop business alignment Requirements
processes
Process Map Team Charter
• Process mapping • Team Charter
• Define Customers
& Stakeholders • Translate critical • Action Plan
customer
• Define critical requirements • Process Maps
customer
requirements • Assess baseline
metrics Action Plan
• Prepare team
Measure:
Define Opportunities
Six Sigma: DMAIC
Measure
Define Analyze Improve Control
Opportunities Performance Opportunity Performance Performance

Objective Main Activities Tools/Techniques Key Deliverables

Process Chart Histogram
• Identify critical • Develop Measurement • Inputs: Process Variables
CCR
measures Plan
• Outputs: Process
• Develop methods for • Plot and Analyze Data Responses
collecting data
• Validate • Data Collection formats &
• Establish baseline Check sheet plans
Measurements Process Map
sigma (variation) for 1.1
processes • Determine desired • Define baseline
1.2
performance performance
1.3

• Collect other
performance items
Action Plan
Analyze:
Analyze Opportunity
Six Sigma: DMAIC

Analyze
Define Measure Improve Control
Opportunities Performance Opportunity Performance Performance

Objective Main Activities Tools/Techniques Key Deliverables

• Analyze Data Control Chart Histogram
• Stratify and • Data Analysis
Analyze Data
• Histogram • Statement of root
• Control charts cause
• Identify and
• Pareto’s
Validate the Root
• Run charts Cause & Effect • Potential solutions
Cause
• Scatter Plot Fishbone Diagram
• Identify Potential
• Identify root cause(s)
Solutions Methods Machine
• Identify potential
solutions
Materials People

Scatter Plot
Improve:
Improve Performance
Six Sigma: DMAIC
Improve
Define Measure Analyze Control
Opportunities Performance Opportunity Performance Performance

Objective Main Activities Tools/Techniques Key Deliverables

Cost Benefit
• Identify solutions • Statement of Solution
• Evaluate and Select
Cost:
Solutions •Installation
• Develop a •Spares • Development of Action
Change Benefit: Plan
• Determine Solution •Productivity Savings

Impacts & Benefits

• Management • Communicate Message
Process Map Gantt Chart
Plan • Communicate solution of Solution using:
1 Task A • Process Map(s)
to all Customers &
• Communicate • Analysis Doc’s
Stakeholders 2 Task B
Improvement • Storyboard
3 Task C
Strategy • Impact & Benefits

Force Field Analysis

Forces for idea Forces against idea

10
Control:
Control Performance
 Six Sigma: DMAIC
Control
Define Measure Analyze Improve
Opportunities Performance Opportunity Performance Performance

Objective Main Activities Tools/Techniques Key Deliverables

• Executive plan Run Charts • Process control
• Develop pilot plan
systems
• Disseminate Lessons
• Summarize
lessons learned Learned • Standards and
experiences and
procedures
lessons. 1 Poor X
• Institute new
2 Late K
process Process Control • Training
• Develop
3 Late Y
institutionalization of
• Determine other • Change implementation
plan
improvement Change Plans plan
opportunities. • Identify continuous
• Continuous
improvement CCR
improvement document
opportunities.
• Standardization

GAP
12
Exercise: Matching Team-Check

Descriptive Statement or Question Answer

Optimize the process or performance.

Process
Model Step States the current performance level.

1.0 Define Identify opportunity that would provide the biggest business
payoff.
Opportunities
Determine an operational definition that states the
2.0 Measure methodology to collect data and the amount of data to be
Performance collect

3.0 Analyze Customer surveys indicate a high level of customer

dissatisfaction, which can be quantified as a cost or loss.
Opportunity
4.0 Improve State how you can sustain the gains you have made.
Performance
Marketing studies have been distributed.
5.0 Control
Performance Disseminate lesson’s learned to ensure replication and
standardization of performance improvements.
Find the inputs that are the largest contributors to the
defective performance.

What is the best solution?

Exercise: Matching Team-Check Answer Key

Descriptive Statement or Question Answer

Optimize the process or performance. 4

States the current performance level. 3
Process
Identify opportunity that would provide the biggest business 1
Model Step payoff.
1.0 Define Determine an operational definition that states the
methodology to collect data and the amount of data to be 2
Opportunities collect
2.0 Measure Customer surveys indicate a high level of customer 1
dissatisfaction, which can be quantified as a cost or loss.
Performance
State how you can sustain the gains you have made. 5
3.0 Analyze Marketing studies have been distributed. 5
Opportunity
Disseminate lesson’s learned to ensure replication and 5
4.0 Improve standardization of performance improvements.
Performance Find the inputs that are the largest contributors to the 3
defective performance.
5.0 Control What is the best solution? 4
Performance
Determine root causes for the identified gaps in 3
performance.
Define the priorities and establish the performance targets. 2