DEFINE
Define is the first phase in the DMAIC model. During the Define phase, the project’s definition is developed. The project’s definition includes the overall scope, objectives, and goals of the project. It also determines the project leader, team members, sponsor, stakeholders, and schedule.
During the Define phase, the process is also defined. This is accomplished utilizing various tools such as flow charts, process mapping, and SIPOC (Suppliers-Inputs-Process-Outputs-Customers).
Teams are formed during the Define phase. Selecting team members is a critical part of the phase. It is important to determine stakeholders and select at least a portion of the team from this group.
The team leader is a critical roll in any six sigma project. It is the leader’s job to keep the team focused on the stated objective, scope, and goal. The team leader also sets the ground rules and ensures conflicts are minimized and resolved.
Many team members may need “Change Agent” training. Because most people fear change, it is critical for team members to have the ability to “influence change” in a positive manner.
The most commonly used tools in the Define phase include:
> Project Charter
> Flow Charts
> Process Mapping
> Work Breakdown Structure (WBS)
> PERT Charts> Affinity Diagram
> Nominal Group Technique (NGT)
> Prioritization Matrix
> Gannt Charts
> Voice of the Customer (VOC)
> CT Trees (Critical to Quality, Critical to Schedule, etc)
> Pareto Charts
> Rolled Throughput Yield (RTY)
> Kano Model
MEASURE
Once the project has been Defined, the second phase of the DMAIC model is Measure .The Measure phase digs below the surface to develop a detailed understanding of the process. Process baselines and sources of opportunities and problems are identified.
To gain a deep understanding of the process, more detailed process level maps are developed. The process level map provides intricate detail of the activities and tasks. Input is gathered from operating employees regarding factors which are critical to quality (CTQ), critical to schedule (CTS), critical to cost (CTC) etc.
During the Measure phase, the factors causing problems are identified. We also determine the conditions and circumstances surrounding the occurrence of the problems, roadblocks, or bottlenecks.
There Measure phase is one of the most time consuming phases of the DMAIC model. It is important to do a thorough job in the Measure phase, as the subsequent phases depend on it.
Data collection is a critical part of the measurement phase. In order to determine the data to collect, the team must decide on the questions they are trying to answer. For example, “how long is the existing wait time?”, “what is the existing process speed at various temperatures?”
There are many tools used in the Measure phase. Some of the most common are:
> Probability and Statistics
> Data Collection
> Measurement Systems
> Process Level Flowcharts
> Process Level Mapping
> Histogram
> Stem and Leaf Plots
> Pareto Charts
> Cause and Effects Diagram and Matrix
> FMEA (Failure Mode and Effects Analysis)
> Control Charts
> Process Capability
> Gage R & R Studies
> Frequency Plots
> Confidence Intervals
> Process Sigma
> Data Collection
> Measurement Systems
> Process Level Flowcharts
> Process Level Mapping
> Histogram
> Stem and Leaf Plots
> Pareto Charts
> Cause and Effects Diagram and Matrix
> FMEA (Failure Mode and Effects Analysis)
> Control Charts
> Process Capability
> Gage R & R Studies
> Frequency Plots
> Confidence Intervals
> Process Sigma
ANALYZE
Once the process is measured and baselines developed, the Analyze phase begins. It is during the Analyze phase where the real problems and opportunities are identified. The previously believed theories and ideas are either confirmed or disproved.
During the measure phase, the conditions and circumstances surrounding problems are determined. The Analyze phase attempts to determine why they are occurring and what can be done to improve it.
The Analyze phase uses more detailed tools for process analysis, such as “root cause problem solving” (RCPS) tools. One example is the cause and effect diagram, often called the Ishikawa diagram.Once the root causes to problems and opportunities are identified, new solution ideas are developed that will be utilized in the Improve phase.
Six sigma has many tools for fully analyze the process to know what is happening, how and why it happens, and what might be done to improve the process.
Some of the most commonly used six sigma tools in the Analyze phase are:
> Brainstorming
> 5 Why’s
> Value Stream Mapping
> Control Charts (XBar & R, np, C, U, p)
> Scatter Plots> Regression Analysis
> Design of Experiments (DOE)
> Hypothesis Testing
IMPROVE
Improve is the fourth phase of the DMAIC model. After the process has been fully analyzed, it is time to improve it.The root causes and factors determined during the Analyze phas are now utilized to improve the process.During the Improve Phase, the solutions to problems and opportunities are developed, implemented, and evaluated.
There are many six sigma tools used in the Improve phase. Some of the most common are:
> Design of Experiments (DOE)
> Hypothesis Testing> Brainstorming
> Cause and Effect Diagram
> Box Whisker Charts
> Process Mapping
> Lean Manufacturing Tools:- Standardized Operations
- SMED (Single Minute Exchange of Die)
- Value Stream Analysis
- Work Simplification
- Methods Improvement
- Error Proofing
- 5S
CONTROL
Solutions are implemented during the Improve phase. The Control phase is utilized to sustain the improvements obtained. Throughout the Control phase, it is common to obtain additional improvements as the new methods are embedded into the operating system.
Control charts are widely used in the Control phase of the DMAIC model. They are used to monitor the improved process and determine when “special causes” are presented.
Common tools utilized in the DMAIC model for Control:
> Control Charts : X Bar & R - I-MR- p- np- c- U- EWMA> Standard Work
> Visual Management
> Performance Management
> Process Mapping
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