DMAIC project template

Franck Strub Equable 6 September 2004

Project name

6 sigma steps (DMAIC)

Define Measure Analyze Improve Control Define your business problem Measure your process (Y) performance Find the root causes (Xs) of the problem Improve, implement new solution 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 Incremental Revenues Labor Savings Material Savings TOTAL Benefits (1 year)

ROI

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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: Team members/role:

Manager: Key stakeholders from Business team:

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

6 Planning
Dates: Gantt

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Define
7 (SIPOC)

Project name Process map & CTQs

process as felt by the customer

Supplier = My Company

Input

Step 1

Step 2

Step 3

Output

My Customer

measurement
CTQ*
Definition Specification limit Performance targets

*Critical To Quality

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Measure
Selected Project CTQ(s):

Project name CTQ details

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: Define Performance standard

What is a defect?

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
Measurement system analysis

Project name Gage R&R

Data Collection plan for Repeatability & Reproductibility study: Data sample size = Date of data collection: 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:

M-step 3: Measurement System Analysis

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
CTQ data collection plan Data sample size = Date of data collection: Where data have been collected? How data have been collected?

Project name CTQ data collection plan

M-step 4: Baseline current (As Is) process capability

Will you take the opportunity to collect obvious Xs when collecting your CTQ measurements? If yes, which Xs: Display an extract of the data collected:

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Measure

Project name Photography of current performance

Continuous CTQ Sample size= Short term data or Long term data? Histogram with Normality test result and descriptive statistics:

M-step 4: Baseline current (As Is) process capability

Type of the distribution (normal, other): Variability represented by its (s,

Trend represented by its (m, median, Q1, Q3, other):

P95, Q1/Q3, other):

Non NORMAL Distribution Observed DPMO= Equivalent ZLT= Equivalent ZST (ZLT+1.5)=

PROCESS CAPABILITY MEASURE: NORMAL Distribution Observed DPMO= Potential DPMO= ZLT = ZST (ZLT+1.5)= Conclusion Problem with trend, variability or both?
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Measure
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:

Project name Photography of current performance

M-step 4: Baseline current (As Is) process capability

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Analyze
Continuous CTQ Normal probability plot:

Project name Graph analysis

A-step 5: 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
Improvement Goal Target (from benchmark) for: Trend: Variability: LT DPMO or LT %defects= Yield (%)= ZLT= ZST=(ZLT+1.5)=

Project name Set expected performance

A-step 6: Define Performance Objectives of To Be process

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
Process (AS IS) detail analysis: Detailed process map

Project name Process analysis

A-step 7: Identify Xs (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
List of potential significant Xs

Project name Potential root causes

A-step 7: Identify Xs (root causes)

Label C/N/X on your fishbone, then rate every X impact vs implementation (table below)

Fishbone diagram of my Y
Measurements Materials Men

Y/CTQ Output

Environment

Methods

Machines

Impact High Implementation Easy Low

1 3

2 4

Hard
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Analyze
Results of segmentation (continuous CTQ only) : (Box plots, Scatter plots, Distributions per X)

Project name Segmentation analysis

A-step 7: Identify Xs (root causes)

Conclusion:

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Analyze
Pareto chart of the CTQ categories:

Project name Pareto analysis

A-step 7: Identify Xs (root causes)

Conclusion: Pareto chart of the defect categories:

Conclusion: FMEA:

Conclusion:
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Analyze
Statistical Tests Performed
Test 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 Xs: X Factors p value

Project name Hypothesis testing

A-step 7: Identify Xs (root causes)

%contribution

conclusion

Financial benefits confirmation (Update your Business case):

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Improve
List of Vital few Xs (screening DOE):

Project name Improvement actions

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

Transfer function:

I-step 9: Discover Variable relationships (if necessary)

Proposed Solution: Optimal Settings

Confirmation runs capability:

I13

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

X tolerance settings:

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Control
C-step 11: Define and Validate Measurement System on Xs (if necessary)
Control on one X (yes/no): If yes, X measurement system analysis:

Project name Gage R&R on Xs

Data Collection plan for Repeatability & Reproductibility study: Data sample size = Date of data collection: 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
C-step 12: Determine new Process Capability
Process or Product new capability: Continuous CTQ: NORMAL Distribution Observed DPMO= Potential DPMO= ZLT = ZST (ZLT+1.5)=

Project name Confirmation of improved performance

Non NORMAL Distribution Observed DPMO= Equivalent ZLT= Equivalent 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
C-step 13: Implement Process Control
Control Charts (SPC) in place/review mechanisms:

Project name Process controls

Mistake Proofing action taken:

FMEA control actions in place:

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