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DMAIC – a logical flow to problem solving An iterative approach © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Define the Problem Measure the Process Analyse Improve Control Gain project approval Close the project
The flow of the Define Phase Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval “To develop a clear project charter based on a real problem that is relevant to the customer, and that will provide significant benefits to the organisation.” © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Define Phase Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval How does the problem link to the customer? Who? Where? When? How? Are you clear which process the problem relates to? Does the project have the buy-in to proceed and succeed? What’s wrong? What do you want to achieve? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Define Phase Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval How does the problem link to the customer? Who? Where? When? How? Are you clear which process the problem relates to? Does the project have the buy-in to proceed and succeed? What’s wrong? What do you want to achieve? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Define Phase Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval How does the problem link to the customer? Who? Where? When? How? Are you clear which process the problem relates to? Does the project have the buy-in to proceed and succeed? What’s wrong? What do you want to achieve? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Define Phase Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval How does the problem link to the customer? Who? Where? When? How? Are you clear which process the problem relates to? Does the project have the buy-in to proceed and succeed? What’s wrong? What do you want to achieve? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Define Phase Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval How does the problem link to the customer? Who? Where? When? How? Are you clear which process the problem relates to? Does the project have the buy-in to proceed and succeed? What’s wrong? What do you want to achieve? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Define Phase Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval How does the problem link to the customer? Who? Where? When? How? Are you clear which process the problem relates to? Does the project have the buy-in to proceed and succeed? What’s wrong? What do you want to achieve? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential “To understand and baseline the current performance of the process, through a set of relevant and robust measures (KPIs).” © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential When and where does the data come from? How does the process currently behave? Does the data represent what you think it does? What is the current performance of the process with respect to the customer? How do you measure the problem? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential When and where does the data come from? How does the process currently behave? Does the data represent what you think it does? What is the current performance of the process with respect to the customer? How do you measure the problem? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential When and where does the data come from? How does the process currently behave? Does the data represent what you think it does? What is the current performance of the process with respect to the customer? How do you measure the problem? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential When and where does the data come from? How does the process currently behave? Does the data represent what you think it does? What is the current performance of the process with respect to the customer? How do you measure the problem? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential When and where does the data come from? How does the process currently behave? Does the data represent what you think it does? What is the current performance of the process with respect to the customer? How do you measure the problem? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential When and where does the data come from? How does the process currently behave? Does the data represent what you think it does? What is the current performance of the process with respect to the customer? How do you measure the problem? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Analyse Phase Define Measure Analyse Improve Control Analyse the process Develop theories and ideas (possible root causes) Analyse the data Verify root causes and understand cause and effect “To find the root causes of the problem, and understand/quantify their effect on process performance.” © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Analyse Phase Define Measure Analyse Improve Control Analyse the process Develop theories and ideas (possible root causes) Analyse the data Verify root causes and understand cause and effect What does the existing process knowledge say? How does the root cause affect the process output? What does the data say? How does the process actually work? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Analyse Phase Define Measure Analyse Improve Control Analyse the process Develop theories and ideas (possible root causes) Analyse the data Verify root causes and understand cause and effect What does the existing process knowledge say? How does the root cause affect the process output? What does the data say? How does the process actually work? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Analyse Phase Define Measure Analyse Improve Control Analyse the process Develop theories and ideas (possible root causes) Analyse the data Verify root causes and understand cause and effect What does the existing process knowledge say? How does the root cause affect the process output? What does the data say? How does the process actually work? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Analyse Phase Define Measure Analyse Improve Control Analyse the process Develop theories and ideas (possible root causes) Analyse the data Verify root causes and understand cause and effect What does the existing process knowledge say? How does the root cause affect the process output? What does the data say? How does the process actually work? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Analyse Phase Define Measure Analyse Improve Control Analyse the process Develop theories and ideas (possible root causes) Analyse the data Verify root causes and understand cause and effect What does the existing process knowledge say? How does the root cause affect the process output? What does the data say? How does the process actually work? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Improve Phase Define Measure Analyse Improve Control Generate potential solutions Select the best solutions Assess the risks Pilot and implement “To develop, select and implement the best solutions, with controlled risks.” © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Improve Phase Define Measure Analyse Improve Control Generate potential solutions Select the best solutions Assess the risks Pilot and implement Which solutions are most likely to work? When, where and how will the solutions be implemented? What are the risks of implementing the solutions? What are all the different possible solutions? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Improve Phase Define Measure Analyse Improve Control Generate potential solutions Select the best solutions Assess the risks Pilot and implement Which solutions are most likely to work? When, where and how will the solutions be implemented? What are the risks of implementing the solutions? What are all the different possible solutions? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Improve Phase Define Measure Analyse Improve Control Generate potential solutions Select the best solutions Assess the risks Pilot and implement Which solutions are most likely to work? When, where and how will the solutions be implemented? What are the risks of implementing the solutions? What are all the different possible solutions? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Improve Phase Define Measure Analyse Improve Control Generate potential solutions Select the best solutions Assess the risks Pilot and implement Which solutions are most likely to work? When, where and how will the solutions be implemented? What are the risks of implementing the solutions? What are all the different possible solutions? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Improve Phase Define Measure Analyse Improve Control Generate potential solutions Select the best solutions Assess the risks Pilot and implement Which solutions are most likely to work? When, where and how will the solutions be implemented? What are the risks of implementing the solutions? What are all the different possible solutions? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Control Phase Define Measure Analyse Improve Control Implement ongoing measurement Standardise the solutions Quantify the improvement Close the project “To ensure the solutions are embedded, the process has robust controls, and the project has clear closure.” © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Control Phase Define Measure Analyse Improve Control Implement ongoing measurement Standardise the solutions Quantify the improvement Close the project Have the changes become ‘business as usual‘? Does the project have a clear closure process? Has the project goal been achieved? How will the process be measured after the project? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Control Phase Define Measure Analyse Improve Control Implement ongoing measurement Standardise the solutions Quantify the improvement Close the project Have the changes become ‘business as usual‘? Does the project have a clear closure process? Has the project goal been achieved? How will the process be measured after the project? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Control Phase Define Measure Analyse Improve Control Implement ongoing measurement Standardise the solutions Quantify the improvement Close the project Have the changes become ‘business as usual‘? Does the project have a clear closure process? Has the project goal been achieved? How will the process be measured after the project? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Control Phase Define Measure Analyse Improve Control Implement ongoing measurement Standardise the solutions Quantify the improvement Close the project Have the changes become ‘business as usual‘? Does the project have a clear closure process? Has the project goal been achieved? How will the process be measured after the project? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
The flow of the Control Phase Define Measure Analyse Improve Control Implement ongoing measurement Standardise the solutions Quantify the improvement Close the project Have the changes become ‘business as usual‘? Does the project have a clear closure process? Has the project goal been achieved? How will the process be measured after the project? © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
Measurement System Analysis Routemap The tools for assessing the measurement system… Start here Possible actions for improving the measurement system… Rule of tens Minitab’s ‘number of distinct categories’ Check for rounding during data collection. Use full resolution of measurement system. Improve resolution of measurement system (upgrade or replace equipment or system). No Is the resolution acceptable? Yes Attribute GR&R – with a known standard MSA Drilldown Is the level of bias (accuracy) acceptable? No Calibrate the measurement system. Improve/communicate the operational definition. Redesign measurement system to reflect the operational definition. Yes © Copyright QSB Consulting 2007 Gage R&R Study Attribute GR&R Study MSA Drilldown Is the level of precision acceptable? No Same as above, plus: Develop operating procedures for use of measurement system, and train users. Ensure measurement system is fit for purpose. Yes Move on with the project! © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
Process Capability Routemap Calculate the % Defective Clarify if your % defective is short or long term Convert into a Sigma Level Calculate Sigma Shift Continuous Data LSL USL Short Term Short Term Metrics %ST ZST Count Data Bad Good ZSHIFT Sigma Shift 0 1 2 3 Defects © Copyright QSB Consulting 2007 %LT PPM DPMO Long Term Long Term Metrics ZLT Attribute Data You can use the PPM or DPMO metrics to present the % defective in the long term. © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Good Bad
The Process Door Routemap Getting to know the process as it actually happens… - Process Mapping & Value Stream Mapping - Time Value Maps and Value Add Charts - Seven Wastes and Spaghetti Diagrams Assessing what could go wrong and where… - Failure Mode and Effects Analysis (FMEA) Understanding what does go wrong in the process and where… - Affinity Diagrams - Measles Charts Understand which process inputs are critical to customer requirements… - Cause and Effect Matrix Identifying possible root causes… - Brainstorming Structure possible root causes in a logical manner… - Fishbone (Cause and Effect) Diagrams Investigate a defect to understand its root cause… - 5 Whys © Copyright QSB Consulting 2007 © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 The Data Door Routemap For graphical analysis… For statistical analysis… Looking at distributions… - Histogram, Dot Plot - Minitab’s Graphical Summary - Probability Plot Deciding if data fits a particular model… - Normality Test (Anderson Darling) - Individual Distribution Identification Deciding if changes over time are significant… - Statistical Process Control (SPC) - Run Charts Looking for changes over time… - Time Series Plot, Trend Analysis Deciding if groups of data are different, and quantifying the difference… - Confidence Intervals - Hypothesis testing Comparing distributions or groups of data… - Box Plots and Individual Value Plots - Multi-Vari Chart Comparing proportions and percentages… - 100% Stacked Bar Chart Quantifying the relationships between process inputs and outputs… - Correlation & Regression - Simple Regression, Fitted Line Plot, - Multiple Regression, Binary Logistic Regression Looking for relationships between data sets… - Scatter Plot, Matrix Plot - Bubble Plot © Copyright QSB Consulting 2007 Adjusting the process to look for relationships between its inputs and outputs… - Design of Experiments (DOE) Looking at different categories of data… - Pareto Chart © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
Hypothesis Tests for Averages You want to compare the averages of some samples of data to decide if they are statistically different. Start here: Not sure Are the samples Normally distributed ? No You could try transforming the data using Data Transformation. Tukey’s Quick Test For comparing the averages of two samples. Yes OR How many samples do you want to compare ? You could compare the median values of the samples instead. One Two Three or more 1 Sample t-Test For comparing the average of one sample against a specific target or historical average. 2 Sample t-Test For comparing the averages of two samples against each other. One Way ANOVA For comparing the averages of three or more samples against each other. © Copyright QSB Consulting 2007 or Paired t-Test For comparing the averages of two samples that are linked in pairs. © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
Hypothesis Tests for Medians You want to compare the medians of some samples of data to decide if they are ‘statistically’ different. Start here: Yes Are the samples Normally distributed? Don’t forget that you can also test for differences in average. No How many samples do you want to compare? One Two or more Are there any obvious outliers in your samples? © Copyright QSB Consulting 2007 Yes No 1 Sample Sign Test For comparing the median of one sample against a specific target or historical average. Mood’s Median Test For comparing the medians of two or more samples (that have outliers) against each other. Kruskal-Wallis Test For comparing the medians of two or more samples (with no outliers) against each other. © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
Hypothesis Tests for Standard Deviation You want to compare the standard deviation of some samples of data to decide if their variation is statistically different. Start here: Are the samples Normally distributed? No Yes How many samples do you want to compare? Two Three or more Levene’s Test For comparing the standard deviations of two or more samples that are not Normally distributed. F-Test For comparing the standard deviations of two samples that are Normally distributed. Bartlett’s Test For comparing the standard deviations of three or more samples that are Normally distributed. © Copyright QSB Consulting 2007 © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
Hypothesis Tests for Proportions You want to compare the proportions or percentages of different samples of data to decide if they are statistically different. Start here: How many proportions do you want to compare ? One Three or more Two 1 Proportion Test For comparing a proportion against a specific target or historical proportion. © Copyright QSB Consulting 2007 2 Proportions Test For comparing two proportions against each other. Chi-Square Test For comparing three or more proportions against each other. © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
Statistical Process Control - Routemap Start here: What type of data do you have? Continuous Count Attribute Is the data in individuals or in rational subgroups? U Chart For analysing the Count or Defects per Unit (DPU) P Chart For analysing proportions or percentages. Or Or Laney U’ Chart For analysing Counts or Defects per Unit with larger samples Laney P’ Chart For analysing proportions or percentages with larger samples. Individuals Subgroups © Copyright QSB Consulting 2007 I-MR Chart For analysing individual data points X Bar–R Chart For analysing the averages of small subgroups (2-9). X Bar-S Chart For analysing the average of large subgroups (more than 10). OR © OPEX Resources Ltd. 2004-2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906