DMAIC project template

Franck Strub – Equable ©

6 September 2004
 Project name

6 sigma steps (DMAIC)

• Define • Define your business problem

• Measure • Measure your process (Y) performance
• Analyze • Find the root causes (X’s) of the problem
• Improve • Improve, implement new solution
• Control • Deliver Y performance over time

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 Define Project name
Business Problem

1 Pb Statement

Description of the problem (what? where? since when? based on which data?
Based on which facts?)

Voice Of Customer (Customer perception)

Internal perception
Competitors benchmark

2 Goal Statement

Develop Goal statement/opportunity or objective in clear, concise, measurable terms

Demonstrate alignment of the project with the company/business strategy

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 Define Project name
Business Case

3 Business Case
Why to do the project?

What if project not done?

Financial Business Case

What Comment Cost

K€
Project Labor
Project Materials
Project Contractors
Equipment investment
Yearly operation cost
TOTAL Costs 0
Incremental Revenues
Labor Savings
Material Savings
TOTAL Benefits (1 year) 0
ROI 0

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 Define Project name
Project charter

4 Project scope

Project: in scope Project: out of scope

5 Team Green Belt/Black Belt role: Manager:

Team members/role: Key stakeholders from Business team:

Customers:
Others:

Black Belt:
Master Black Belt:
VP Quality / Quality Manager:

6 Planning D M A I C
Dates:
Gantt

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Define Project name
Process map & CTQ’s

7 (SIPOC)

process as felt by the customer

Supplier = My
My Company Customer
Input Step 1 Step 2 Step 3 Output

measurement

CTQ* Definition Specification Performance

limit targets

*Critical To Quality

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 Measure Project name
CTQ details
Selected Project CTQ(s):
M-step 1:
Selected CTQs
Discrete/continuous CTQ?

CTQ Operational Definition(s):

What is it (measurement starting point and end point) ?

How to measure it?

M-step 2: What is a defect?

Define
Performance
standard If applicable to your CTQ, LSL* contractual value or limit defined by customer:

If applicable to your CTQ USL* contractual value or limit defined by customer:

*LSL Lower Specification Limit

*USL Upper Specification Limit

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 Measure Project name
Gage R&R
Measurement system analysis
M-step 3:
Data Collection plan for Repeatability & Reproductibility study:
Measurement
Data sample size =
System Date of data collection:
Analysis Where data have been collected?
How data have been collected?
How many operators? How many repeats per operator?

Gage R&R study – Continuous data:

-Tolerance (USL-LSL):
-Short method (yes/no):
-Gage R&R as %contribution: Gage R&R as %tolerance: Nb of distinct categories:

Gage R&R study – discrete data:

If we have a Known sample (a reference), then how was built the known sample?

Conclusion/decision taken (evidence that the measurement of our CTQ is reliable):

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 Measure Project name
CTQ data collection plan
CTQ data collection plan
M-step 4: •Data sample size =
Baseline •Date of data collection:
current (As Is) •Where data have been collected?
•How data have been collected?
process
capability
•Will you take the opportunity to collect obvious X’s when collecting your CTQ
measurements?
•If yes, which X’s:

•Display an extract of the data collected:

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 Measure Project name
Photography of current performance
Continuous CTQ
M-step 4: •Sample size=
Baseline •Short term data or Long term data?
current (As Is) •Histogram with Normality test result and descriptive statistics:
process
capability

•Type of the distribution (normal, other):

•Trend represented by its (, median, Q1, Q3, other):
•Variability represented by its (P95, Q1/Q3, other):
PROCESS CAPABILITY MEASURE:
NORMAL Distribution Non NORMAL Distribution
Observed DPMO= Observed DPMO=
Potential DPMO= Equivalent ZLT=
ZLT = Equivalent ZST (ZLT+1.5)=
ZST (ZLT+1.5)=

Conclusion
•Problem with trend, variability or both?
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 Measure Project name
Photography of current performance
Discrete CTQ
M-step 4: •Sample size:
Baseline •Short term data or Long term data?
current (As Is) •Process capability
•Yield (%)=
process •%defects=
capability •DPMO=
•Opportunities per unit=
•DPU=
•Equivalent ZLT=
•Equivalent ZST (ZLT+1.5)=
•95% confidence interval on DPMO:

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 Analyze Project name
Graph analysis
Continuous CTQ
A-step 5: •Normal probability plot:
As Is process
Graph Analysis

Conclusion (can we detect a true process and an unstable process?):

All type of CTQ

•Stability over time/Run chart:

Conclusion:
•Pb of technology (short term common causes)?
•Pb of control (long term shift due to special causes)?
•Both pbs?
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 Analyze Project name
Set expected performance
Improvement Goal
A-step 6: Target (from benchmark) for:
Define Trend:
Performance Variability:
LT DPMO or LT %defects=
Objectives of Yield (%)=
To Be process ZLT=
ZST=(ZLT+1.5)=

Gap (Improvement – Actual)

DPMO gap or Defect reduction factor:
Z gap=

6 Sigma tools necessary to meet performance objectives:

• Ground fruit: Logic and Intuition
• Low hanging fruit: Basic tools (Process Map, CE/CNX fishbone diagram, SOP,
FMEA, Pareto, Histogram, Box plot)
• Bulk of Fruit Process Characterization and Optimization
• Sweet Fruit: Transform the project into a DFSS project

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 Analyze Project name
Process analysis
Process (AS IS) detail analysis:
A-step 7: •Detailed process map
Identify X’s
(root causes)

Conclusion

•CTQ Intermediate distribution plot (continuous CTQ only)

Conclusion

Standard Operation Procedures analysis:

•Exist:
•Are applied:
•Incitation to apply them exist:
•Training has been given to operators:

Policy analysis:
•Exist
•Are applied

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 Analyze Project name
Potential root causes
List of potential significant X’s
A-step 7:
Identify X’s Label C/N/X on your fishbone, then rate every X impact vs implementation (table below)
(root causes) Fishbone diagram of my Y

Measurements Materials Men

Y/CTQ Output

Environment Methods Machines Impact

High Low
Implementation
Easy 1 2
Hard 3 4
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 Analyze Project name
Segmentation analysis
Results of segmentation (continuous CTQ only) :
A-step 7: (Box plots, Scatter plots, Distributions per X)
Identify X’s
(root causes)

Conclusion:

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 Analyze Project name
Pareto analysis
Pareto chart of the CTQ categories:
A-step 7:
Identify X’s
(root causes)

Conclusion:

Pareto chart of the defect categories:

Conclusion:

FMEA:

Conclusion:

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 Analyze Project name
Hypothesis testing

A-step 7: Statistical Tests Performed

Identify X’s Test X Factors p value %contribution conclusion
(root causes) one sample or two sample T-test
Annova one way
Homogeneity of variance
Chi square test
Simple regression
Non parametric data test
ANOVA 2 ways
GLM
DOE screening

Conclusion/Prioritized list of significant X’s:

Financial benefits confirmation (Update your Business case):

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 Improve Project name
Improvement actions
List of Vital few Xs (screening DOE): Improvement action plan (Who What When):
I-step 8:
Screen potential
causes.
List improvement
actions/projects

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Improve Project name
Improved performance

I-step 9:
Transfer function:
Discover
Variable
relationships
(if necessary) Proposed Solution: Optimal Settings

Confirmation runs capability:

I13

X tolerance settings:
I-step 10:
Establish
Operating
Tolerances
(if necessary)

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Control Project name
Gage R&R on X’s
C-step 11: Control on one X (yes/no):
Define and If yes, X measurement system analysis:
Validate
•Data Collection plan for Repeatability & Reproductibility study:
Measurement Data sample size =
System on X’s Date of data collection:
(if necessary) Where data have been collected?
How data have been collected?
How many operators? How many repeats per operator?

•Gage R&R study – Continuous data:

-Tolerance (USL-LSL):
-Short method (yes/no):
-Gage R&R as %contribution: Gage R&R as %tolerance: Nb of distinct categories:

•Gage R&R study – discrete data:

If we have a Known sample (a reference), then how was built the known sample?

•Conclusion/decision taken (evidence that the measurement of our X is reliable):

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 Control Project name
Confirmation of improved performance
C-step 12: Process or Product new capability:
Determine new
Continuous CTQ:
Process NORMAL Distribution Non NORMAL Distribution
Capability Observed DPMO= Observed DPMO=
Potential DPMO= Equivalent ZLT=
ZLT = Equivalent ZST (ZLT+1.5)=
ZST (ZLT+1.5)=

Discrete CTQ:
•Sample size:=
•Short term data or Long term data?
•Process capability
•Yield (%)=
•%defects=
•DPMO=
•Opportunities per unit=
•DPU=
•Equivalent ZLT=
•Equivalent ZST (ZLT+1.5)=
•95% confidence interval on DPMO

Statistical Confirmation of Improvement (by statistical test):

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Control Project name
Process controls
C-step 13: Control Charts (SPC) in place/review mechanisms:
Implement
Process
Control

Mistake Proofing action taken:

FMEA control actions in place:

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