Define Phase

Responsibility
Leadership team /
Project selection Linked to Business goals (BBS, KPI, Customer issues)
process owners
Leadership team /
Draft project charter Problem description (Compelling case for the project)
mentor/ Coordinator
To define the process & product scope. Inputs identification
SIPOC Team
& possible data collection objects
To map micro (small 'y') from (big 'Y'). It clearly establishes
CTQ Tree &
operational definition of measure for CTC / CTB. Also Team
Specification table
establishes defect definition
Finalize project
At minimum it should contain the following -
charter

Problem description, Why this project, Goals and Measures

(Both for Big 'Y' & 'y'), team members, expected business
Team, mentor
benefit, expected customer benefit, project timeline,
consequential metrics, can also include support requirement

Measure Phase

To identify suspected 'X's for inclusion in data collection

Use Prioritization
planning along with data on 'y'. Identification of stratification
matrix OR FMEA
factor to be included in data collection plan
In prioritization matrix, use input variables from SIPOC and
process variables from Process steps in SIPOC

In FMEA, recognize potential failure modes are non

fulfillment of CTQs. Severity rating of effects of potential
failure modes should be based on scope of the project (Not
based on AIAG Manual). Take the highest severity score for
RPN calculation). Causes are listed for potential failure
Team & Stakeholders
modes and not for the effects. Frequency of occurrence of
cause is scored thru brainstorming at this stage. Existing
controls & Detection ranking should be based on current
process. Don't hang up on absolute value of RPN and select
relatively high RPN.

Prepare spreadsheet with 'Y', 'y' and causes identified in

Data collection
earlier step, can include stratification factor in data collection Team & mentors
planning
plan

Sample size for continuous data - N=(2s/d)^2, where s is the initial

determination estimate of the std deviation and d is the accuracy required.

For discrete data, N=(2/d)^2*p*(1-p), where p is the initial

proportion defective.
As much as good data as possible - Collect
Use stratified sampling as per the proportion of total volume
Sampling strategy
(population size)
For continuous data use gauge R&R, should be less than
Do MSA
30%
For discrete data, use Kappa, >= 0.6
 For system generated data, validate system data with few
primary data. If DOES NOT match, scrap system data and
collect new data.
For continuous data, check for Normality, if Normal and
Look at pattern in the
Chronological, use individual control charts to identify
data
special causes
For continuous data, if either Non-normal or Non-
chronological, use box plot, the whiskers suggest the
presence of outliers.
If outliers can be explained and actions to prevent
recurrence can be implemented, implement actions as quick
hit solutions after RISK Analysis.
If you are unable to take actions and ignorant about the
causes, then those special causes are Common causes for
us. Live with them.
For discrete data, use Pareto chart.
For continuous and Normal data, go to capability analysis
Calculation of sigma
normal, put specifications options, click activate Z-bench.
level
Sigma rating = Z-bench+1.5
For continuous data, Non-normal, Fit a distribution and
repeat the above steps
If the data does not fit any distribution, go to capability
analysis normal, look at the observed performance and read
the Zst value from the table.
If the data is discrete, calculate DPMO and read Zst value
from the table. Caution - try to take O = 1 (1-Yft) as
proportion defective.

Analysis Phase

Detailed process To identify process variables affecting CTQs and for cycle
mapping time projects - to identify VA / NVA activities
NVA activities are defined if it does not match any of the
following conditions
Customer is not willing to pay for that activity, It doesn't
change the shape of the output, not done right first time

Organising for Cause Effect diagram, Why Why analysis, or a combination

causes of the two called "Tree Diagram"

Validation of the Gemba investigation, observing frequency of occurrence of

causes the causes, rework FMEA if necessary
Data based validation
Both Y & X is continuous, do simple linear regression
Y - Continuous, Xs - Continuous, do Multiple linear
regression
Y- Normal, testing for
Y - Continuous, X - Discrete in 2 categories
variances, do F test
Y- Normal, testing for
mean, do 2 sample T
test
 Y - Not normal, for
testing for variances, do
levene's test
Y - Not normal, for
testing of averages, do
Median test in Kruskal -
Wallis
Y- Normal, testing for
Y - Continuous, X - Discrete in more than 2 categories variances, do Bartlett's
test
Y- Normal, variances are
equal, for testing for
means, use ANOVA
Y - Not normal, for
testing for variances, do
levene's test
Y - Either Not normal or
variances are not
equal,for testing of
averages, do Median
test in Kruskal - Wallis
Chi-Square Test with
hypothesis with x & y as
Y - Discrete, X - Discrete
independent against they
are dependent
Y - Discrete, X - Continuous use Logistic regression

Design of For optimizing Y on basis of X's, Usually applicable in Mfg,

Experiments but can be used for model building in IT/ITES

Improve Phase Generate Solutions for validated causes

Prirotize solutions
Pilot (if possible)
Risk Analysis
Implementation planning

Control Phase Revise existing processes and standards (documents)

Recognize dominance pattern of the process and establish
appropiate controls
Control mechanism for monitoring of Y's
Evaluate results - Before & After, validate results
Develop plans for institutionalization and horizontal
deployment
Document the project and share with stakeholders
Handover