Chapter 2.
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Introduction to DMAIC
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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
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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
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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
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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
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A
Analyze
I
Improve
C
Control
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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
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Improve
12 Concentration Chart
Variable Search
C 13
Control 14 Full Factorial
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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
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2.0 – Introduction to DMAIC
DMAIC Process – skeleton of the 6s process
D
Define
M
Measure
A
Analyze
The process gains: Variation Analysis
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Ensure solution is sustained
I 20 Control Chart
Improve
21 Pre-Control Charts
22 Process Control Analysis
C
Control 23 Mistake Proofing
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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
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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
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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
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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
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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
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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
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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
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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
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End of Chapter 2.0
Clarifications if any
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