equable dmaic template july 2004

8/2/2019 Equable DMAIC Template July 2004

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Franck Strub Equable

6 September 2004

DMAIC project template


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Equabletous droits rservs. Copyrights Equable. Six Sigma Consulting2

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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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

1 Pb Statement

Business Problem

Develop Goal statement/opportunity or objective in clear, concise, measurable termsDemonstrate alignment of the project with the company/business strategy

2 Goal Statement

Define


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Why to do the project?

What if project not done?

Financial Business Case

Business Case

3 Business Case

What Comment Cost

K

Project Labor

Project Materials

Project Contractors

Equipment investment

Yearly operation cost

TOTAL Costs 0

Incremental RevenuesLabor Savings

Material Savings

TOTAL Benefits (1 year) 0

ROI 0

Define


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Green Belt/Black Belt role:Team members/role:

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

Manager:Key stakeholders from Business team:

Customers:Others:

4 Project scope

Project: in scope

D M A I CDates:Gantt

Project: out of scope

Project charter

5 Team

6 Planning

Define


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7 (SIPOC)

Process map & CTQs

process as felt by the customer

Input Output

Supplier =My Company

Definition Specification Performancelimit targets

CTQ*

Step 2Step 1 Step 3

measurement

*Critical To Quality

My

Customer

Define


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M-step 1:

Selected CTQs

Selected Project CTQ(s):

Discrete/continuous CTQ?

CTQ Operational Definition(s):

What is it (measurement starting point and end point) ?

How to measure it?

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:

M-step 2:DefinePerformancestandard

MeasureCTQ details

*LSL Lower Specification Limit*USL Upper Specification Limit



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M-step 3:

MeasurementSystemAnalysis

Measurement systemanalysis

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 CTQ is reliable):

MeasureGage R&R



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M-step 4:

Baselinecurrent (As Is)processcapability

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

Will you take the opportunity to collect obvious Xs when collecting your CTQmeasurements?

If yes, which Xs:

Display an extract of the data collected:

MeasureCTQ data collection plan



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

Type of the distribution (normal, other):

Trend represented by its (m, median, Q1, Q3, other):Variability represented by its (s, P95, Q1/Q3, other):PROCESS CAPABILITY MEASURE:NORMAL DistributionObserved DPMO=Potential DPMO=ZLT=ZST (ZLT+1.5)=

Conclusion

Problem with trend, variability or both?

M-step 4:Baselinecurrent (As Is)processcapability

Photography of current performanceMeasure

Non NORMAL DistributionObserved DPMO=Equivalent ZLT=Equivalent ZST (ZLT+1.5)=



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Discrete CTQSample 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:

MeasurePhotography of current performance

M-step 4:Baselinecurrent (As Is)processcapability



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Continuous CTQNormal probability plot:

Conclusion (can we detect a true process and an unstable process?):

All type of CTQStability over time/Run chart:

Conclusion:Pb of technology (short term common causes)?Pb of control (long term shift due to special causes)?

Both pbs?

A-step 5:As Is processGraph Analysis

AnalyzeGraph analysis



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A-step 6:DefinePerformanceObjectives ofTo Be process

Improvement GoalTarget (from benchmark) for:

Trend:Variability:LT DPMO or LT %defects=Yield (%)=ZLT=ZST=(ZLT+1.5)=

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

AnalyzeSet expected performance



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A-step 7:Identify Xs

(root causes)

Process (AS IS) detail analysis:Detailed process map

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:ExistAre applied

AnalyzeProcess analysis



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List of potential significant Xs

Y/CTQ Output

Men

Machines

Materials

Methods

Measurements

Environment

Fishbone diagram of my Y

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

1 2

3 4

Impact

High Low

Implementation

Easy

Hard

AnalyzePotential root causes


(root causes)



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

Conclusion:

AnalyzeSegmentation analysis


(root causes)


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Pareto chart of the CTQ categories:

Conclusion:

Pareto chart of the defect categories:

Conclusion:

FMEA:

Conclusion:

AnalyzePareto analysis


(root causes)


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Statistical Tests PerformedTest X Factors p value %contribution conclusion

one sample or two sample T-testAnnova one wayHomogeneity of varianceChi square testSimple regressionNon parametric data testANOVA 2 waysGLM

DOE screening

Conclusion/Prioritized list of significant Xs:

Financial benefits confirmation (Update your Business case):

AnalyzeHypothesis testing


(root causes)


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I-step 8:Screen potentialcauses.List improvementactions/projects

List of Vital few Xs (screening DOE): Improvement action plan (Who What When):

ImproveImprovement actions


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I13

X tolerance settings:

I-step 9:DiscoverVariablerelationships(if necessary)

Transfer function:

Proposed Solution: Optimal Settings

Confirmation runs capability:

I-step 10:Establish

OperatingTolerances(if necessary)

ImproveImproved performance


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Project nameControlGage R&R on Xs

C-step 11:Define and

ValidateMeasurementSystem on Xs(if necessary)

Control on one X (yes/no):

If yes, X measurement systemanalysis:

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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C-step 12:Determine new

ProcessCapability

Process or Product new capability:

Continuous CTQ:

NORMAL DistributionObserved DPMO=Potential DPMO=ZLT=ZST (ZLT+1.5)=

Discrete CTQ:Sample size:=Short term data or Long term data?

Process capabilityYield (%)=%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):

Confirmation of improved performanceControl

Non NORMAL DistributionObserved DPMO=Equivalent ZLT=Equivalent ZST (ZLT+1.5)=


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E bl t d it C i ht E bl Si Si C lti

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C-step 13:Implement

ProcessControl

Control Charts (SPC) in place/review mechanisms:

Mistake Proofing action taken:

FMEA control actions in place:

Process controlsControl

equable dmaic template july 2004

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