DMAIC Project Template Project Name: Project Owner:

Project Progress Tracking D1. Map Project D2. Approve Project M1. CTQ Characteristics& Standards M2. Measurement System Analysis M3. Data Collection A1. Baseline Process A2. Performance Objective A3. Identify Drivers of Variation I1. Screen for Vital Xs I2. Screen for vital Xs I3. Define Improved Process C1. MSA on Xs C2. Improved Process Capability C3. Establish Control Plan Key Deliverables: List of Customer(s) and Project CTQs Team Charter High Level Process Map (COPIS) CAP Plan (Optional) Preliminary CBA, if applicable QFD / CTQ Tree Operational definition, Specification limits, target, defect definition for Project Y(s) Data Collection Plan Measurement System Analysis Baseline of Current Process Performance Normality Test Statistical Goal Statement for Project List of Statistically Significant Xs List of Vital Few Xs Transfer Function(s) Optimal Settings for Xs Confirmation Runs/Results Tolerances on Vital Few Xs MSA Results on Xs Post Improvement Capability Statistical Confirmation of Improvements Process Control Plan Process Owner Signoff Final CBA, if applicable Tollgates: Planned Completed 10/June/2010 11/March/2010 mm/dd/yyyy XXXXXX 15/March/2010 Steps: Tools: Survey Focus Groups Interviews ARMI, Stakeholder Analysis In/Out of Frame Threat vs. Opportunity Matrix Other ______________ Continuous Gage R&R Attribute Gage R&R Sample Size Calculator Basic Statistics Histogram Dot Plots Box and Whisker Plots Run Charts Normality Testing Continuous/Discrete Zst, Zlt Benchmarking Detailed Process Mapping Moments of Truth Nature of Work Flow of Work Fishbone Hypothesis Testing Regression Analysis DOE Pugh Matrix New Process Mapping FMEA on new process Process Modeling / Simulation Continuous Gauge R&R Discrete Gauge R&R Control Charts CAP Plan Control Plan Define Measure Analyze Improve Control OVERVIEW Project Progress Tracking

Define Deliverables DEFINE Map the Project Project Charter SIPOC Process Map Communication Plan ARMI/RASIC Terms & Acronyms Used Project Charter Map the Project

Key Output Characteristics Important to Customer (CTQ's) DEFINE Project Mapping Customer Sample Comments Key Output Characteristics Important to Customer (CTQ's)

High Level Project Plan DEFINE Project Charter Business Case In Scope Out Scope Problem Statement Goal Statement High Level Project Plan Target Date Actual Date Start Date Define Measure Analyze Improve Control

DEFINE Terms & Acronyms Used Indicators Definition

ARMI DEFINE Key Stakeholders Define Measure Analyze Improve Control When Populating the Stakeholder, consider the ARMI: A= Approver of team decisions R= Resource or subject matter expert (ad hoc) M= Member of team I= Interested Party who will need to be kept informed

DEFINE Communication Plan Message Audience Media Who When

Process Map DEFINE

DEFINE COPIS Customer Output Process Input Supplier

Measurement System Analysis (MSA) Measure Deliverables Process Capability Measurement System Analysis (MSA) Data Collection Plan

Data Collection Plan MEASURE Mode of Collecting Data Y Operational Definition Defect Definition Performance Standard Specification Limit Opportunity Mode of Collecting Data Y Data Type Unit of Measurement Decimal Places Database Container Existing/New Database If new, when would the database be ready Planned Start date for Data Collection Equipment Used for Measurement Equipment Calibration Info Responsibility Training Need Operation Details

Measurement System Analysis Minitab Descriptive Statistics Rule Rule Description Acceptable Result A R&R % of Tolerance < 10% B % Contribution (R&R Std deviation) Smaller than Part to Part Variation C Number of distinct categories >=4 Overall Gage Result

Process Capability MEASURE

Basic Analysis for Project Y ANALYZE Analyze Deliverables MSA results of Impacting Factors Hypothesis Summary Checking for Impact of Xs on Y Basic Analysis for Project Y DCP for Potential Xs Fishbone Identify Potential Xs

Cause & Effect Diagram ANALYZE

Visualization plot Used ANALYZE DCP for Potential Xs Outlining Data Collection Steps for Xs Potential Cause Type of Data Collection Method Test to be Used Visualization plot Used

Basic Data Analysis for Project Y ANALYZE Basic Data Analysis for Project Y Randomness & Shape Study Randomness Study Normality Study

Basic Data Analysis for Project Y ANALYZE Basic Data Analysis for Project Y Spread & Central Tendency Study Spread Study Central Tendency Study

Checking for Impact of x1 on Y ANALYZE Checking for Impact of x1 on Y Statistical Interpretation of Relationship Graphical Depiction Hypothesis Result Inference:

Checking for Impact of x2 on Y ANALYZE Checking for Impact of x2 on Y Statistical Interpretation of Relationship Graphical Depiction Hypothesis Result Inference:

Checking for Impact of x3 on Y ANALYZE Checking for Impact of x3 on Y Statistical Interpretation of Relationship Graphical Depiction Hypothesis Result Inference:

Checking for Impact of x4 on Y ANALYZE Checking for Impact of x4 on Y Statistical Interpretation of Relationship Graphical Depiction Hypothesis Result Inference:

Checking for Impact of x5 on Y ANALYZE Checking for Impact of x5 on Y Statistical Interpretation of Relationship Graphical Depiction Hypothesis Result Inference:

Summary of Impacting Factors ANALYZE Hypothesis Summary Summary of Impacting Factors S. No. Factor p – Value Graphical Tool Used Inference Next Steps

MSA Results of Impacting Factors ANALYZE MSA Results of Impacting Factors Checking the validity of data of the Impacting Factors S. No. Factor MSA Method Used MSA Result RCA for Problems Next Steps

Improve Deliverables IMPROVE Screening of the Impacting Factors Improve Summary – Take Aways Pre-Post Analysis of Factor Pre–Post Analysis of Project Y Basic Analysis of Improved Y Action Plan for Improving the Factors Screening of the Impacting Factors

Screening of Impacting Factors IMPROVE Screening of Impacting Factors Prioritize the Impacting Factors

Action Plan for Improving the Factors IMPROVE Action Plan for Improving the Factors S. No. Pain Area Root Cause Improvement Idea Implementation Owner Implementation Status

Basic Data Analysis of Improved Y Randomness & Shape Study Randomness Study Normality Study

Basic Data Analysis of Improved Y Spread & Central Tendency Study Spread Study Central Tendency Study

Pre – Post Analysis of Project Y IMPROVE Pre – Post Analysis of Project Y Statistical Validation of Improvement Graphical Depiction Hypothesis Result Inference:

Pre – Post Analysis of Project Y IMPROVE Pre – Post Analysis of Project Y Statistical Validation of Improvement Graphical Depiction Hypothesis Result Inference:

Pre – Post Analysis of Factor IMPROVE Pre – Post Analysis of Factor Statistical Validation of Improvement Graphical Depiction Hypothesis Result Inference:

Pre – Post Analysis of Factor IMPROVE Pre – Post Analysis of Factor Statistical Validation of Improvement Graphical Depiction Hypothesis Result Inference:

Pre – Post Analysis of Factor IMPROVE Pre – Post Analysis of Factor Statistical Validation of Improvement Graphical Depiction Hypothesis Result Inference:

Pre – Post Analysis of Factor IMPROVE Pre – Post Analysis of Factor Statistical Validation of Improvement Graphical Depiction Hypothesis Result Inference:

Pre – Post Analysis of Factor IMPROVE Pre – Post Analysis of Factor Statistical Validation of Improvement Graphical Depiction Hypothesis Result Inference:

Improve Summary – Take Away

Control Deliverables CONTROL Control Plan & FMEA on Control Plan Cost Benefit Analysis and Sign Off Control Charts & Inference (for X2) Control Charts & Inference (for X1) Establish Process Capability Basic Analysis of Improved Y Control Charts & Inference for Y – Pre & Post Time Series Study of Y – Pre & Post Control Plan & FMEA on Control Plan

Control Plan & FMEA on Control Plan What’s Controlled Goal/Spec Limits Control Method Who/What Measures Where Recorded Decision Rule / Corrective Action SOP

Time Series Study of Y – Pre & Post CONTROL

Control Charts & Inference for Y – Pre & Post

Basic Data Analysis of Controlled Y Randomness & Shape Study Randomness Study Normality Study

Basic Data Analysis of Controlled Y Spread & Central Tendency Study Spread Study Central Tendency Study

Establish Process Capability CONTROL Establish Process Capability Process Capability – Post Implementation Z Bench (Long Term Sigma) Short Term Sigma (Long Term Sigma + 1.5)

Control Charts & Inference (x1)

Control Charts & Inference (x2)

Cost Benefit Analysis & Sign Off CONTROL Cost Benefit Analysis & Sign Off Benefit Source Unit Benefit Units Impacted Total Benefit Cost Reduction Enhanced Revenues Labor Reduction Decreased Overhead COPQ Reduction

APPENDIX

Stakeholder Analysis Want to see More Of Want to see Less Of

RASIC

RASIC Chart for Define & Measure CONTROL RASIC  RASIC Chart for Define & Measure Activities Team Members Pre- DMAIC Collect VOC from all stakeholders   Conduct Stakeholder analysis Collect data for the last 12 months Analysis of data Report out on the Pre DMAIC Analysis DEFINE Create Project Charter Send Charter for Executive Approval Approve Charter Build SIPOC Build Process Map MEASURE  Build the data collection plan  Get the DCP Approved  Approve DCP  Collect Data  Validate data Publish next steps to stakeholder Responsible (R) : Solely and directly responsible for the activity (Owner) - Includes approving authority (A) Approve (A) : Reviews and assures that the activity is being done as per expectations Support (S) : Provides the necessary help and support to the owner Inform (I) : Is to be kept informed of the status/progress being made Consult (C) : Is to be consulted for this activity for inputs

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