Chapter 2.

0
Introduction to DMAIC

1
 2.0 – Six Sigma 3 Dimensions
D M A I C
Define Measure Analyze Improve Control

Driven
by
Custome METHODOLOGY
r Needs

Led by
Senior
Management
ORGANIZATION TOOLS

Enabled by Quality Team

2
 2.0 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

• Objective of Six sigma Initiative is

• To have all measurable outcomes of the Processes

operate at “Six Sigma level”

• To have all attribute outcomes of the Processes

operate at “Zero defect”

• The Key to achieving the Six sigma level is the

application of the DOE tools

3
 2.0 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

What is Important to the
D customer: 1 Project Charter
Define Define Problem
Team formation
Establish Goal 2 SIPOC / Process Mapping
M Construct Process Flow
Measure
3 Process FMEA

A
Analyze

I
Improve

C
Control
4
 2.0 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

D
Define
How well we are doing: 4 Pareto Chart
Collect data
M 5 Calibration
Validate the MSA
Measure Gauge R&R Studies
6

A
Analyze

I
Improve

C
Control
5
 2.0 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

D
Define

M
Measure
The Process: 7 Paired Comparison
Analyze the data
8 Process Parameter Search
A Identify Root causes
Analyze 9 Component Search

10 Modified Component Search

I Multi Vari Analysis
11
Improve
12 Concentration Chart

Variable Search
C 13
Control 14 Full Factorial
6
 2.0 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

D
Define

M
Measure

A
Analyze
The Process performance 15 B vs. C
measure :
16 ANOVA
I Prioritize root cause
Improve Innovate pilot solution 17 Scatter Plot
Validate the improvement
18 RSM
C
Control
7
 2.0 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

D
Define

M
Measure

A
Analyze
The process gains: Variation Analysis
19
Ensure solution is sustained
I 20 Control Chart
Improve
21 Pre-Control Charts

22 Process Control Analysis

C
Control 23 Mistake Proofing
8
 1.3 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

• Once the Project is selected, the first step is we need to

DEFINE the Problem

• The next step is to use DOE techniques to pinpoint the

root cause(s) of the problem. This is done in MEASURE
AND ANALYZE phase

9
 1.3 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

• Once the root cause(s) are pinpointed, we have to plan

and implement Process improvement actions. This is
done in IMPROVEMENT phase. Root cause(s) are also
validated in this phase

• Once the Process improvement actions are

implemented, we need to ensure that the actions stay
permanent in process. This is done in CONTROL phase

10
 1.3 – Introduction to DMAIC

DMAIC Process – Case 1

Project: Side face Unclear after grinding
Define phase

1 Problem Statement Unclear after Side face grinding operation

2 Part Number X2134B
3 Response Attribute type (Not measurable)
4 Historic rejection 2.5%
5 Specification Not Applicable

11
 1.3 – Introduction to DMAIC

DMAIC Process – Case 1

Project: Side face Unclear after grinding
Define phase
6 Instrument used Visual
7 Is R&R study required No
8 SSV’s (Suspected 1. Side face grinding
Sources of Variation) 2. Gas nitriding
3. Pre nitriding
4. Pointage of electrolysis solution
5. Temperature of bath
6. Current
7. Ring Location
8. Operator skill
12
 1.3 – Introduction to DMAIC

DMAIC Process – Case 1

Project: Side face Unclear after grinding
Measure and Analyze phase

DOE tools used to find out the cause. The root cause is
established
Current in Pre-nitriding should be 110 amps instead of 150
amps
Pointage should be 55
Temperature should be 35
Root cause(s) are validated based on the above finding
13
 2.0 – Introduction to DMAIC

DMAIC Process – Case 1

Project: Side face Unclear after grinding

Improve Phase

Process setting changed to the specification identified in the

M&A phase

Control Phase

Process Monitoring for the above parameters

14
 2.0 – Introduction to DMAIC

How the root cause(s) are pinpointed

Sources of Variations

Poor Product
Process Input Material Poor Process
Design
Variations variations design (Tolerancing)

Parameter Method Processing Environment

Machine Tooling
variation variation material

Six Sigma initiative, helps to zero in on the sources of variations using the DOE
15
tools to reduce the variation and achieve Zero defect
 2.0 – Introduction to DMAIC

DMAIC Process – skeleton of the 6s process

• The key phases in DMAIC are
• Measure and Analyze
• Improvement
• It is very difficult to tell the amount of investment
required in implementing the Process improvement
action,since this is known only after “pinpointing the
root cause(s)”
• The whole cycle of DMAIC for each project should be
completed in a maximum duration of three months
16
 End of Chapter 2.0

Clarifications if any

17