DMAIC

Focused Improvement
Nestlé Continuous Excellence
Agenda

1. What is DMAIC?
2. What is a belt?
3. Why do we use DMAIC?
4. How do we use it?
5. How do I find out more?

TPM/FI – DMAIC 2 V1.0

 DMAIC Methodology Principles and Steps
Steps Sub-steps
DMAIC provides a systematic and structured 5-step • Define Problem and Target
problem solving approach that can be used to • Define Financial and Non Financial
Impact
analyse and reduce all losses Define • Define Team and Timelines
• Map skills

• Plan data collection

Ensure results are sustainable Define precisely • Collect data
in the long term the scope of Measure • Assess data reliability
(process standardisation) the project • Identify areas of focus

• Restore basic conditions

Analyse •
•
Identify the root causes
Verify the root cause with data or fact

Implement actions to Understand and describe

solve root causes and more precisely the • Elaborate & Prioritise action plan
verify effectiveness problem • Execute Action Plan
Improve • Evaluate Target achievement
• Evaluate solution effectiveness

• Standardise improvements
Identify and verify the • Transfer Knowledge to people
root causes Control • Monitor actions and improvements

TPM/FI – DMAIC 3 V1.0

DMAIC Relies on Three Key Principles

Logical and rigorous project management

Decisions based on facts and data whenever
possible
Teamwork, ongoing coaching, and engagement of
staff
“Better with a team!“
“Impossible!“

TPM/FI – DMAIC 4 V1.0

When do we use DMAIC?

To solve problems that

Are aligned with the business needs
Are reoccurring and repetitive
We may have tried to solve in the past
Don’t have a known root cause.
Cannot be solved using a day to day continuous improvement
approach (Go See Think Do)

TPM/FI – DMAIC 5 V1.0

Agenda

1. What is DMAIC?
2. What is a belt?
3. Why do we use DMAIC?
4. How do we use it?
5. How do I find out more?

TPM/FI – DMAIC 6 V1.0

What is a belt?

A Belt (White, Yellow, Green and Black Belt) is an

internal certification recognising that an individual is
competent to lead a problem solving project using
DMAIC methodology.

The ‘Belt’ recognises project management skills, the

proper application of systematic and structured
methodology (DMAIC) with the respective tools,
leveraging the teams knowledge and delivering
sustainable results.

TPM/FI – DMAIC 7 V1.0

Why do we have different belt levels?

As problems are different in complexity and scope, they

require different toolsets and leadership skills.
As the complexity of a problem increases number and
complexity of tools must also increase.
The level of knowledge in the application of tools
increases with the colour of the
belt, starting with White Belt
through Yellow, Green and
Black Belt.

Slide extracted from FI Reference Guide

v3.1

TPM/FI – DMAIC 8 V1.0

Agenda

1. What is DMAIC?
2. What is a belt?
3. Why do we use DMAIC?
4. How do we use it?
5. How do I find out more?

TPM/FI – DMAIC 9 V1.0

DMAIC in NCE

Once losses have been identified, it is important to reduce them in a

sustainable way.

Using DMAIC ensures root causes have been identified, the

improvements implemented achieve results, and the results are
sustainable.

It can be used for very simple problems, involving a single piece of

equipment, as well as highly complex issues that involve the entire
value chain Optimise Value Stream

Operations Management System

Consumer Marketing
& Customer & Sales Supply Chain Manufacturing Procurement Agriculture

TPM + LEAN

TPM/FI – DMAIC 10 V1.0

 DMAIC is one of the FI methodologies for analysing
and eliminating losses

1. Identify, prioritise and assign projects to

achieve business objectives - IPA
Identify
losses

2. Identify losses (Loss Tree Analysis – LTA*)

Trainings Competences

DMAIC Advanced Black Belt

DMAIC Intermediate Green Belt

3. Analyse and solve problems (DMAIC projects) DMAIC Basic 2 Yellow Belt

DMAIC Basic 1 White Belt

Analyse and
Eliminate
losses
4. Analyse and reduce changeover times
(SMED* – Single Minute Exchange of Dies)

considered for being applicable beyond Manufacturing for the time being
TPM/FI – DMAIC 11 V1.0
FI Pillar Mission

ZERO WASTE
ZERO WASTE
ONE TEAM
100% ENGAGEMENT
100% ENGAGEMENT

TPM LEAN

FOCUSED IMPROVEMENT
PLANNED MAINTENANCE

EDUCATION & TRAINING

LEAN VALUE STREAM

EARLY MANAGEMENT
SAFETY, HEALTH &
MAINTENANCE

LEAN DESIGN

LEAN OFFICE
AUTONOMOUS

ENVIRONM.

QUALITY
GOAL ALIGNMENT
LEADERSHIP DEVELOPMENT
COMPLIANCE

Mission
Define and deploy focused improvement methodologies and tools across
the factory aligned with business needs to assure efficient and sustainable
capability to identify, analyse and eliminate losses.

TPM/FI – DMAIC 12 V1.0

Agenda

1. What is DMAIC?
2. What is a belt?
3. Why do we use DMAIC?
4. How do we use it?
5. How do I find out more?

TPM/FI – DMAIC 13 V1.0

 Project Selection Process
GA FI LEAN
Different
Escalated issues Loss Tree Value Stream
Sources of Potential from Reviews Analysis Design
Others

Improvement Projects

Operational
Master Planning Project Selection Tool
Including Scoping
Outputs: & Prioritisation (from FI)
• Top priority projects selected aligned with
strategic goals (OMP + IPA)
Project
Project methodology defined (GSTD,
DMAIC Trainings
•
Selection
Advanced DMAIC

DMAIC levels, SMED, TPM and LEAN Intermediate DMAIC

Knowledge

Sponsor
Basic DMAIC 2

tools) and project leader assigned with the

Process
Basic DMAIC 1

Go-See Think-Do

appropriate competence Time

• Trainings needs identified and fed into the

factory capability building plan
• Integrated into Technical division/ Factories
resource capacity planning (Project Leader,
Project Coach and Project Sponsor)

TPM/FI – DMAIC 14 V1.0

DEFINE: Define the Project

Goal
Define the project’s
purpose and scope and
put it in a business context

Output
A clear statement of the
intended improvement and
how it is to be measured

TPM/FI – DMAIC 15 V1.0

MEASURE: Measure the Current Situation

Goal
Focus the improvement
effort by gathering
information on the current
situation (historical data)

Output
1 to 2 focused problem
statements

TPM/FI – DMAIC 16 V1.0

ANALYSE: Analyse to Identify Causes

Goal
Identify root causes and verify
them, using facts and data

Output
A theory that has been tested
and verified

TPM/FI – DMAIC 17 V1.0

IMPROVE: Implement Solutions & Evaluate Results

Goal
Develop, test and implement
solutions that address the identified
root causes
Use data to evaluate the
implemented solutions

Outputs
Implemented solutions which
eliminate or reduce the impact
of identified root causes
A comparison of the planned to the
actual implementation

TPM/FI – DMAIC 18 V1.0

CONTROL: Standardise and make future plans

Goal
Maintain the gains through
standardisation of work methods and
processes
Anticipate future improvements
and capture the lessons of this
project

Outputs
Before and after data analysis which
shows the impact of the improvement
Standardisation of improvements
Training of new methods
A control plan for ongoing monitoring
of results
Documentation and communication of
results, learnings and
recommendations

TPM/FI – DMAIC 19 V1.0

Agenda

1. What is DMAIC?
2. What is a belt?
3. Why do we use DMAIC?
4. How do we use it?
5. How do I find out more?

TPM/FI – DMAIC 20 V1.0

How do I find out more?

Your local FI Pillar leader at market or factory level

should be able to answer any of your questions on
DMAIC.

TPM/FI – DMAIC 21 V1.0