DMAIC Methodology ‘Sasadhar Bera, lIM RanchiWhat is DMAIC ? ‘The acronym DMAIC represents the five phases in the Six-Sigma methodology: 0 : Define NS Analyae 1 typrove ©: Contrel DMAIC & @ structured problem-solving methodology widely used in product, process or service improvement, MAIC structure encourages creative thinking about the problem, DMAIC: Measure Phase ‘The measurement phase has the purpose of mapping the current process and establishes metrics that describe the tical to quality (CTa) characteris, ‘A critical to quality (C1Q) is a product oF service characters that is important tothe customer. Foran aluminium fol manutactrer, the CTA characterises |. Ultimate tensile strength |. Thickness of fost 1 Flongation Iu Surface smoothness DMAIC: Define Phase ‘The following steps are performed during the define phase ofthe DMAKC methodology |. Define escape and boundaries ofthe project, 1, Define detects ii Establish projet charter Iu Estimate the impact ofthe project in manctary terms It often useful to map the process in order to understare the process and locate the problems. The projet charter ‘must be corepleted in the define steps. The project charter ‘will be created by project Champion. The same charter wil ‘be refined bythe Champion and Black Belt TQ Characteristics of a Credit Card Business For credit card service, the foliwng ae the CTO characters (rom customers’ perspective I Speed of service: Needed information should be written ‘when applying fr 2 card. Response from bank should be within the specified tme perio. I. Ease-of-use: Easy to use and hasslefree, features, creat lof credit ar. li, Accurate and consistent: Accurate, timely, and easy to understand the moathi biting process. Iv. Customer serdce: Accessible, responsive and ‘brofesiona staff membersDMAIC: Measure Phase —. ‘The following tops ae carried out during Measure phase: |. Map the process. Kent Key process input varlables (PINS) and key process output variates (KPOVS) 1. fine performance standard of output vartabls ly) 1. Determine baseline sigme performance level Iv-Porform measurement system analysis and determine ‘measurement system capability Perform cause and effect analyse. DMAIC: Analyze Phase ‘Te purpose of the analyze phase isto start learning about data inorder to fire out the possible root causes and their relationship to outputs (5. The data collected from the ‘measure phase are used in the analysis phase. Data set With lative long period of te is helpful to reveals full ‘ange variation in the long cur. |. Determine process capability, throughput, and cycle |. Analyze data to understand reasons for variation and Identity potential root causes. it, Formulate hypothesis and statistically test them to verify potential oot causes, DMAIC: Measure Phase. Wi Determine the ita few factors x) to be measuied, analyzed, improved and controlled for bottom line results Prepare data collection plan Intaty the process map is prepared at a mace level, and usually consists of fe to ton steps. If the team needs further detail for some key steps, it can map ‘them further, creating sub stops foreach macro step. ‘The team usually identifies important process Input and output variables during the process mapping work MAIC: Analyze Phase lw. Determine the sources where greater degiee of aration exists, Fyaluate cause and effec eationship. Understand the felationship among. the factors oF potential root [A process capability study is conducted ta measure how well the process is capable of meeting the customer specication. ‘The team then looks data and other evidence for suspected cause. The hypothesis can be refined or rejected unti the we root cause is identified and verified swith dataDMAIC: Analyze Phase... Muitivari study helps to understand the relationship among diferent factors. Discreteevent simulation is another powerful tool useful in the Analyze phase t's particularly useful in service and ‘transactional busines, Successful applications of crete ‘event simulation are scheduling problems, wating line models, estimate of ele ine, and throughput et. Failure mode and effect analysis (FMEA) is a useful tool ‘uring the analyze phase. FMEA Is used to proce the diferent potential sources ol vatablity,fallures, errors or Select ia product or process. DMAIC: Improve Phase In the improve phase, 2m figures out how to change the process so that developed Solution in the analyze phase Gn be implemented, and thereby improve. the performance of te process. ach process change I teste wth 9 confirmatory study to verify that the presicted improvement. ima take several rounds of improvements tO reach the desires level of performance. MAIC: Analyze Phase. ‘One ofthe big challenge in the Analyze sep Ist use the {ight tools. When the relationship between the problem and otter factors is complex and hidden, more advanced Statistical techniques may be required to identify and verify the cause. DMAIC: Improve Phase The following steps are carried out during!engrove phase | Find out the vital few x5 that lnpact the outout iy Discover relaonship among the va few xs and output, Determine the optimuen level of vital few x's by structurally ‘hanging the operating eves. scabishthe operating tolerances onthe vital few, iv. Generate potential saltions. evaluate and select the most suitable solution for Implementation verify the gin by lle study.DMAIC: Improve Phase —. ‘Before even beginning to develop solution, many teams go back to ther charters and masify their problem and scope of the project based on a better understanding of the problem andthe process Design of experment (DOE) is one of the most important statistical tool in the improve phase. DOE can be applied ‘ether to an actual physical process oF to a computer Simulation model. DOE determines the setting levels of factors that influence the outcome of the process and ‘optimal combination factor settings. DMAIC: Control Phase Iv, Fetablsh key process measures that gle current performance ofthe proces. 1. Reassessed the process capability, UL Establish and implement statistical grocess control (SPC) method in order to maintain longterm gain. DMAIC: Control Phase ‘The objective ofthe control phase is to ensure thatthe Improved performance of the process is sustained after ‘the sicsigma team has completed its work and hand over ‘the new process othe process owner. ‘A control plan or standardized document has to be placed 1 old the gains‘ from the new proces. 1. Develop a dacument to make mistake proof proces ik. Monitor or control he ext process characterises {4 Develop out af conto action plan. Tools Required in Six-Sigma ‘She-Sigma Tools in ManufacturingTools: Define Phase a) Project plan or charter ») Project Management «) Process mapping Tools: Analyze Phase 4} Exploratory Data Analysis (EDA) 1) Confidence interval and Hypothesis test 6) Inferences — Continuous, Atribute {Comparison Test — Continuous and Atibute ‘} Cowelation and Simple regression 4) Multiple Regression @) ANova 1) Variance Components 4) Bootstrapping |) Muttwarate Osta Analysis (MVA) _ (Principle component, Discriminant, Factor, Cluster, Mult! mensional sealing) Tools: Measure Phase 2) Mocess flow chart or Process Mapping Process Cele Tne © ey process att np & ott) © Vale aed activ and Non-valve added ast, ) Basic Tals | © 7C tools © 7 Management and planning to's «) Measurement System Analysis (Gage R&A) {4} Process Capabilty and Process Performance Sigma Level Performance Measurement 4) allure Mode and Efec Analysis (FMEA) 6} Cause fect Atatrx and Quality Function Deployment (QFD) Tools: Improve Phase 4) Design of Experiment (002) — Factorial, Fraction, Miure et » Taguchi's Techniques )_ Response Surface Methodology (RSM) é ‘Simulation mode!Toots: Control Phase 4) Short un and Target Control chart ') cUSUMA, EWM contol chart ©) Control Plan and Others Strategles (Mistake-Profing) © Pola Yoke © Kaizen © Theory of constraints (TOC), © Kanban