TPM COACHES COURSE

BASIC DMAIC
Introduction
 Basic DMAIC in the Context of TPMN

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DMAIC

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QUALITY
Basic
DMAIC
DMAIC across all pillars
GOAL ALIGNMENT
LEADERSHIP DEVELOPMENT
COMPLIANCE
Basic DMAIC is part of Focused Improvement (FI) but is applied all across TPMN

TPM/FI – Basic DMAIC 1 2

 What is DMAIC?

DMAIC provides a simple, structured 5-step problem-

solving approach
Control
Ensure results are sustainable Define
in the long term Define precisely the Solve problems linked to a
(process standardisation) scope of the process that are recurring/
project repetitive and aligned with the
business needs

Improve Measure
Implement
Solve problems that don't have a
Understand and
actions to solve known root cause and cannot be
describe
root causes and more solved using a day to day
verify precisely the continuous improvement
effectiveness problem approach
Analyse
Identify and verify the root
causes

TPM/FI – Basic DMAIC 1 3

 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

Adhering to these principles increases the likelihood of

success and buy-in across the organisation

TPM/FI – Basic DMAIC 1 4

 Overview of Tools at Each DMAIC level
Manufacturing
LEVELS OF DMAIC METHOD

PHASES GSTD BASIC 1

BASIC 2 INTERMEDIATE ADVANCED
SMED Basic 1

Time Series Plot Trends and Seasonality

VOC SIPOC
DEFINE Project Time line Kano
CTQ Communication Plan
Skill Matrix

Data Collection Plan Descriptive analysis

Data reliability
Changeover Data Collection Control Charts
(Operational Definition, *Gage Sampling Plan
MEASURE Registration Form Form (I-MR,xbar-R)
R&R) Advanced Gage R&R
Spaghetti Diagram Pareto Charts Process Capability
Complete Process Capability
Process Map Tree Diagram
IS/IS NOT
Design of Experiments –
Flowchart Full and Fractional
Hypothesis Tests
Brainstorming Factorials / EVOP
Brainstorming (Chi-Square / T test )
Cause & Effect Changeover Data Transformation
Cause and Effects Affinity Diagram Confidence Interval (Normal)
ANALYSE 5Whys analysis form
Diagram Prioritisation Matrix Scatter Plot
Action Plan ECRS Response Surface
5 Whys Matrix of Correlation
One Point Statistical Modeling
Lesson Simple Regression Analysis (ANOVA, Multiple Linear
Regression)

Prioritisation
IMPROVE 5W2H (Action Plan) Planning Tools
FMEA

Standardisation
(One point lessons, SOP, Poka Yoke, and OCAP
CONTROL
others) Control Charts
Skill Matrix

Excel Minita
b
TPM/FI – Basic DMAIC 1 5
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 – Basic DMAIC 1 6

DEFINE Roadmap
PROCESS OBJECTIVE TOOLS
Definition
• 5W1H
Problem • Define scope of problem • Is & Is not
Scope and
• Project Charter

Definition • Identify/confirm the project KPIs

Target • Evaluate trends over time (historical data) • Time Series Plot
• Define target
Evaluation
Impact • Evaluate current losses (financial impact)
• Financial Sheet
Financial • Define tangible and intangible benefits

• Create multidisciplinary team with the

Definition
• Team Charter
right skills to solve the problem
Team

Skill Matrix • Map the team’s initial skills • Skill Matrix

Planning
Time • Define clear activities and deadlines • Time Plan

Gain Approval • Obtain approval to proceed • WB Toll gate

review
Measure

TPM/FI – Basic DMAIC 1 7

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 – Basic DMAIC 1 8

 MEASURE Roadmap
PROCESS
criteria OBJECTIVE TOOLS
stratification • Identify how to stratify the data • Stratification
Identify (by time, area, symptom, etc)

No Yes • Make sure data is consistent,

Is the data
reliable? reliable and detailed enough
for stratification stratification
collection plan data for • Identify and collect baseline • Data Collection
data required for stratification
1. Create data 2. Use historical
Plan & Form

(stratification) • Plot cumulated graph

Data Analysis • Plot project KPIs over time
• Pareto Chart
• Time Series Plot
• Map your process steps to
Mapping
• Flow Chart
ensure team understanding
Process
Statement
Problem • Define focused problem • Focused Problem
statements to achieve project
Focused Statement
target
Gain Approval • WB Toll
• Obtain approval to proceed gate review
Analyse
TPM/FI – Basic DMAIC 1 9
 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 – Basic DMAIC 1 10

 ANALYSE Roadmap
PROCESS OBJECTIVE TOOLS
conditions
machine • Identify and eliminate possible problems • Just do it
Restore basic

problems
focused • With team participation, list all potential
causes for all causes of the focused problems • Brainstorming
List possible (identified in Measure)
problem
focused • Group similar potential causes in a • Cause-Effect diagram
clear, visual way
causes for the
Group possible (fishbone)
problem
focused • Detect root causes from the cause-
• 5 Whys
causes for each
effect diagram using the 5 Whys method
Detect the root
the root causes
Verification of • Verify root causes with facts and data • Go & See in Gemba*

Gain Approval
• Obtain approval to proceed • WB Toll
gate review
Improve
*It’s not a tool, and it’s not Go See Think DO
TPM/FI – Basic DMAIC 1 11
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 – Basic DMAIC 1 12

IMPROVE Roadmap
PROCESS OBJECTIVE
root causes
TOOLS
solutions to the • Propose actions to solve each identified • Brainstorming
Identify
root cause • Prioritisation Process

actions • Prioritise the actions according the impact • Impact x Effort

and effort required to implement Matrix
Prioritise the

• Define actions, deadlines and • Action Plan

plan
Build the action responsibilities for the execution of the (5W2H)
solutions
action plan • Implement and verify the execution of the • Action Plan (5W2H)
action plan – Update the status
Execute the

• Verify effectiveness of solution with data Before/After

Was the target • Times Series Plot
achieved? (Was the target achieved?)
• Pareto Chart
Yes No
Redo measure
Gain Approval or analyse phase • WB Toll
gate review
• Obtain approval to proceed
Control
TPM/FI – Basic DMAIC 1 13
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 – Basic DMAIC 1 14

CONTROL Roadmap
PROCESS OBJECTIVE TOOLS
changes
• SOP, OPL
Standardise • Create or update standards
• Mistake proof
standards
• Check list
• Identify training required for affected people
the new
• Transfer knowledge through training • Training
• Project Storyboard
Communicate

benefits • Review financial impact of the • Update financial

improvements
Evaluate the
sheet
plan in place
• Implement preventative actions to avoid
Put a control
reoccurrence
skill matrix • Update skills matrix with new knowledge
Update the
acquired by the team during the project • Update Skill Matrix
replication
learning and • Forward lessons learned for possible • SWOT Analysis
Share replication in other lines
Gain Approval • WB Toll
• Obtain approval to proceed
gate review
Celebrate Success

TPM/FI – Basic DMAIC 1 15

Task Description in DMAIC Methodology
Steps Tasks
DEFINE • Define scope and problem
• Review historical data; define
shortfall and target
• Evaluate financial impact
• Identify project team
• Prepare schedule
MEASURE • Break down problem into
smaller problems
(stratifications)
• Collect data
• Map process steps
• Define focused problem
statement
TPM/FI – Basic DMAIC 1 16
Results Expected Tools
• Problem, gap and target • Time Series Plot
identified • Financial Sheet
• Financial impact forecasted • Team Charter
• Project team established • Skill Matrix
• Gaps of knowledge mapped • Time Plan
• Time plan for various project
stages drawn up
• Stratification criteria definition • Stratification Criteria
• Data collected (where • Data Collection Plan
needed) &Form (5W1H
• Shared understanding of • Pareto Chart
process and sequence of • Flow Chart
steps
• Priority problems defined
Task Description in DMAIC Methodology

Steps Tasks Results Expected Tools

• Restore basic conditions • Potential causes • Just do it
• List potential causes of focused identified and grouped • Brainstorming
ANALYSE problem • Root causes detected • Cause-Effect Diagram
• Group similar potential causes • 5 Whys Tool
• Verify root causes with data • Go & See (Gemba)
• Propose solutions for root causes • Solutions prioritised - 5W 2H
IMPROVE • Prioritise solutions • Action Plan completed - Impact x Effort matrix
• Build action plan • Actions executed
• Implement actions
• Verify effectiveness of solution • Target verified -Time Series Plot/Bar
Chart or Pareto
• Standardise process changes • Process changes • Operating Instructions
• Train and communicate standards standardised • OPLs, Provisional
• Review financial impact • Control plan Standards, Maintenance
• Implement performance monitoring implemented Plan
CONTROL • Financial impact • Financial Sheet
• Identify possibility of replication
analysis updated with • SWOT analysis
• Summarise project and
actual
recommendations for future
• Corrective Action Plan

TPM/FI – Basic DMAIC 1 17

What Are Your Key Learnings?

Control
Ensure results are Define
sustainable in the long Define
term (process precisely the
standardisation) scope of the
project

Improve
Implement
actions to Measure
solve root Focus the
causes problem

Analyse
Identify root causes

TPM/FI – Basic DMAIC 1 18

 Basic DMAIC Storyboard
DMAIC Storyboard

D M A I C
FIWG Basic Condition Standardisation
Data collection plan Restoration Identify solutions
Leader, Team, (if applicable) (Just do it &
(Standards,
To each root cause
Sponsor, Coach Action plan) OI, OPL)

Project subject Stratification criteria Prioritise solutions Training

List potential causes
(define KPI) (Impact x Effort matrix) of teams
Pareto (Brainstorming)

Time Series Plot Build Action Plan Skill matrix after

(target calculation Process Group similar causes (5W 2H ) Project
and definition) Mapping (Fishbone Diagram) conclusion

FIWG Skill Matrix % Implemented Financial

Before Focused problem Detect root causes Actions benefits
Statement
(5W 1H ) (5 Why’s& Gemba)
Verify target
Financial evaluation Achievement SWOT
(before and After)

Project Schedule Additional

Coaching Reports
Documents

TPM/FI – Basic DMAIC 1 19

Example: Basic DMAIC Storyboard

TPM/FI – Basic DMAIC 1 20