Digital Six Sigma DMAIC Improvement Process

Objective Main Activities Potential Tools and Techniques Key Deliverables

Validate/develop Team Charter Team Charter  Team Charter
Validate or refine the business Map process
opportunity and charter, illustrate
Business CaseOpportunity Statement
 Project Plan
 Identify Quick Wins/Non Value Added Goal StatementProject Scope
 Process maps
their business processes, define  Translate VOC/VOB to CTQs/CTPs Project Plan Team Selection
 Quick Win Opportunities
Gap

customer requirements, and  Build the team Action Plan Project Focus
 CCRs - CTQs CTPs
prepare themselves to be an Sigma Goal (CCR) TASKS
TASKS
I I I . TIONS
ACTIVITIES RESP. START DUESTATUS &ACTION
ACT V T ES RESP START DUESTATUS &AC
S
$$

effective project team

CCRs

 Identify input, process, and output UCL  Input, process, and

Identify critical measures that are indicators Input Process Output CCR

necessary to evaluate the success output indicators

Sigma=
 Operational definitions
of meeting critical customer  Develop Measurement Plan & operational Input
Checksheets
A B
A B
X
 Measurement Plan
requirements, develop a definitions Indicator A1
A1 A B  Cause & effect Diagram
Measurement Plan to effectively  Measurement Systems Analysis A1D1
D1 LCL
 Baseline performance
collect data, and establish  Evaluate baseline performance D1
D2
D2 Sigma=

 Process Process D2 CCR

Indicator
Control & Capability Process A2
A2
baseline performance Indicator A2 X

Output Indicator

Gap

 Identify potential root causes  Results of data analysis

Identify and validate the root causes
of poor performance. Determine
sources of variation and potential
Validate root causes Quantified Root Causes
 Validated root causes
 Use statistical tools  Potential solutions
 Comparative Methods
50%

failure modes that lead to customer Indicators &

 SOV studies Problem Problem
dissatisfaction Y=f(Xs)  FMEA Statement Statement

 Regression analysis
25%
(effect)
 Control charts
Pr oc es s/P rod uct : FM
M
M EA Dat e: ( or igi nal )
FMEA T ea m:
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Risk P riori tyyy

Bla c kk Be lltt: PPPaaagggeee::
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Detect iooonnn
Severi tyyy

Risk P riorit y
OOOccccccuuurrrrrr
eeetteeecccttiooonnn
O ccurre

eeennnccceee D
Seve rrriityyy
Pr oc e ss Ac t ions Re sult s

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Ite m P otentiaall P otennttial P otentiaall
CCCuuurrr reen
nt RReeccoom - Reesspoon nsibility AAAccc t iooonnn P rocceessss Faiillure EEE
ffffff ectss of Ca uuussseee((( s) Connttrollss m endeedd a nd TTTaaarrr ge tt
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ps M ode FFaa iiillluuurrr e ooff Fa
iluuurrr e Action C
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T
Tootal Risk Pri ori ty Resu lt in g Risk Pri ori

 Design of Experiments (screening/RSM)  Solutions to implement

ittyy

Surface Plot of
Cost Benefit
Y11 Costs
Identify, evaluate, and select the
 Implementation Plan
100
$9,000
Energy-saver light bulbs
Generate solutions
50
Y11
llation by employee

right improvement solution(s). To 0-1.5

1.01.5 Ins taof lost production
Cost Gantt Chart (Pilot)
 Improvement impacts
 Evaluate and select solution(s) including
-05.0.00.5 X2
.5
-1.0 -0 0 .0
X1
0.5
1.0
1.5
-1.0
-1.5
500
1,5
00
develop a change management benefits Total cost
$11,000 What
Task Jan
When
Feb Mar Apr
Who
May Responsibility
and benefits
approach to assist the organization Communicate solution(s) to stakeholders Ben efits - Year 1
$5,000
Reduce electric bill by 8%
A
B
Jim
Sue

in adapting to the changes  Prepare Implementation Plan

1,800
W arranty for 5 years
$6,800
C

D
Lynn

Bill/Jim
Total benefits
introduced through solution Idea
Forces Working for
Forces Working
against Idea

implementation

Implement the solution(s), develop a Error Modes and Effects Analysis  Process control plan to
Implement solution
Err or Mode s and Effects A nalys is

Error Mo de Ef fect Analysis Descript ion:

Implemented Solution
maintain gains
(EMEA)

Process Control
lan to maintain the gains, identify
Step s
Proces Degree of Ef fect (Coucenterm
Occu rren easu
Preven re)
ti on

 Verify results of solution

Err or C ause Effect
S tep#

p
Fr equency

Detectio n
Sever ity

System
Total

Assemb
outboundle all • Back
dur inginjury
lif t • nCarr y -all
ot available • injuries,
Back 0 • mailroom
Purchase tw o new carr y -alls fo r

replication and standardization  Integrate and manage solution(s) in daily  Solution(s)

+
4.2.1 container s in • Foot and toe • L ifting lost time, 2 • Include topic in new safety film

results
staging area injur y from g uidelines insur ance 2 4 3 9
dr opped n ot fo llo wed expen
se cont.

Opportunities for
Determine • N on-standar d • V end or • Container • In spect f or non-standard pallets
and cor rect pallet used p allets kep t stack over 2 + return to vend ors
pallet size
4.2.2 end o f 2

opportunities, and provide closure to work processes

fall w hen
pallet and
being lif ted 4 1 1 6
Position • Full p allets • Pallet set 9 0° • Back and 2 • Up date and clarify pallet placement

 Identify replication and standardization

in marked
4.2.3 empty pallet

area of
90° by hand
are r otated
p osition ed -
o ff when
lif t truck
lost time, 3
hand injuries, +

insur ance 5 4 1 10
• In clude topic in new saf ety film
pr ocedures

replication and
the team effort.
lo ading dock can ’t access expen se
and rewo rk
• Stack • Container s • Up date and clar ify loading guid elines

standardization
Stack • First lay er 0
outbound not g uidelines fall w hile
n ot used being lif ted +
container s on completed 1
4.2.4

opportunities
pallet not to befor e 1 1 1 3
exceed tw o starting
high second lay er
Load pallets in • Tie d own • T ie down • In jured 0 • Up date and clarify loading guid
elines vehicle with lines g uidelines fin ger s, +
4.2.5 lif t tru ck and damag e bulk n ot clear damaged 1

 Closure activities
secure mail wh en outbo und 1 2 1 4
tightened mail CCR

Project Workplan CCR

X
Gap

Sigma Goal (CCR)

Gap