Problem

Solving Methodology

DMAIC

Confidential - Rockwell Automation 1

 Learning Objectives 2

• Understand why using a methodology is

important to problem solving

• Understand the definition of the term DMAIC

• Be able to apply the DMAIC principles to your

project
The Problem Solving Goal... 3

Sweet Fruit
Use of a Detailed Methodology

Bulk of Fruit
Process Characterization &
Optimization

Low Hanging Fruit

Basic Tools of Problem Solving

Ground Fruit
Intuition and Logic
Goal Alignment Means Knowing & Doing 4

Right Projects

+ Right People

+ Right Tools

+ Right Support

= Right Results
 Working The Right Projects 5

Right Projects Set

Assess & Deploy &
Performance
Select Measures Dig

+ Right People

+ Right Tools
The Right Projects Means…
+ Right Support • Customer & Business Alignment
• Goals Established
• SMART
= Right Results
Aligning The Right People 6

Right Projects

Align
+ Right People Resources
Prioritize &
Train
Deploy &
Develop

+ Right Tools

+ Right Support
The Right People Means…
• Knowledge appropriate to task
• Required level of skills
= Right Results
• Positioned & able to impact
 Applying The Right Tools 7

Right Projects

Waste Variation
DMAIC
+ Right People Elimination Reduction

+ Right Tools

+ Right Support
The Right Tools Means…
• Proper tool applied to the
= Right Results
problem
• Minimized non-value added
• Reduced process variability
 Providing The Right Support 8

Right Projects

Project Reward & Knowledge

+ Right People Reviews Recognition Management

+ Right Tools

Right Support The Right Support Means…

+ • Projects completed on time
• Appropriate behavior rewarded
= Right Results
• Best practices shared
Why Use an Improvement Method? 9

DMAIC

– Provides a framework
– Provides common language
– Provides a checklist to prevent
skipping critical steps
– Allows you to improve how you
improve
Overview of DMAIC 10

5 1
CONTROL DEFINE

IMPROVE MEASURE

4 2
ANALYZE
3
 DEFINE: Define the Project 11

• Goal
– Define the project’s
purpose and scope and
get background on
the process and customer 5 1
• Output CONTROL DEFINE
– A clear statement of the
intended improvement and
how it is to be measured IMPROVE MEASURE

– A high level map of the process 4 2

ANALYZE
– A translation of the “Voice of the
Customer” into “Key Quality 3
Characteristics”
 DEFINE, (continued) 12

• Thought Process

Calculate
Develop Create
Preliminary
Project Process
Financial
Charter Map
Measurement
 MEASURE (the current state) 13

• Goal
– Focus the improvement
effort by gathering
information on
the current situation
• Output
– Focus 5 1
– Data that pinpoints problem location CONTROL DEFINE
or occurrence
– Baseline data on how well the
process meets customer needs IMPROVE MEASURE
– Understanding of how current 4 2
process operates ANALYZE
– A more focused problem statement 3
 MEASURE, (continued) 14

• Thought Process

Plot defect
Create & stratify
Collect baseline data
frequency plots
data on defects over time and Create detailed
and do Pareto
and possible analyze for process maps
analysis
causal factors special
(if appropriate)
causes
 ANALYZE: to Identify Causes 15

• Goal
– Identify root causes 5 1
and confirm them CONTROL DEFINE
with data
IMPROVE MEASURE

• Output 4 2
ANALYZE
– A theory that has
3
been tested and
confirmed
 ANALYZE, (continued) 16

• Thought Process

Statistical
Develop a
Brainstorm Organize methods to
focused
potential potential Collect data quantify
problem
causes causes cause-effect
statement
relationship
 IMPROVE: Implement Solutions & Evaluate Results 17

• Goal
– Develop, pilot, and implement solutions
that address root causes
– Use data to evaluate both the solutions
and the plans used to carry them out 5 1

• Output CONTROL DEFINE

– Planned, tested actions that eliminate
or reduce the impact of the identified
root causes IMPROVE MEASURE
– Before and After data analysis that 4 2
shows how much of the initial gap was ANALYZE
closed
– A comparison of the plan to actual 3
implementation
 IMPROVE, (continued) 18

• Thought Process

Brainstorm
many
possible Select Develop
Pilot plan(s)
solutions to solution(s) plan(s)
identified
root causes

Evaluate the
Implement Quantify benefits of
plan(s) results the
improvement
 CONTROL 19

• Learning Objectives
– Maintain the gains by standardizing
5 1
work methods or processes
– Anticipate future improvements CONTROL DEFINE
and preserve the lessons from
this effort
– Recognize need for a control plan IMPROVE MEASURE

• Output 4 2
ANALYZE
– Documentation of the new method
– Training in the new method
3
– A system for monitoring its
consistent use and for checking the results
– Completed documentation and communication
of results, learning, and recommendations
 CONTROL, (continued) 20

• Thought Process

Develop and Build Summarize Make

document Ongoing process for and recommen-
Train
standard monitoring updating communicat dations for
practices procedures e learnings future plans
 The DMAIC Cycle 21

Define
• Why must this project be done NOW?
• What is the business case for this project?
• Who is the customer?
• What is the current state?
Control
• What will be the future state? Measure
• During the project, how will I control
• What is the scope of this project? • What are the key metrics for this
risk, quality, cost, schedule, scope,
• What are the intangible deliverables? business process?
and changes to the plan?
• What is the due date? • Are the metrics valid and reliable?
• What types of progress reports
should I send to sponsors? • Do we have adequate data on
• How do I assure that the business this process?
goals of the project were • How will I measure progress?
accomplished? • How will I measure ultimate
• How will I maintain the gains success?
made?

Improve
• What is the work breakdown structure for
this project?
• What specific activities are necessary to
meet the project’s goals?
• How will I re-integrate the various sub-
projects?
• Do the changes produce the desired
effects?
• Any unanticipated consequences?
Analyze
• Current state analysis
• Is the current state as good as the
process can do (entitlement)?
• Who will help make the changes?
• What resources will we need?
• What could cause this change effort
to fail?
• What major obstacles do I face in
completing this project?