6  Methodology: DMAIC Robert Setaputra

PDCA / PDSA PDCA / PDSA is a continuous quality improvement tool. PDCA is introduced by Shewhart. PDSA is Deming’s version of PDCA.

PDCA

Plan Plan (What) Identify the problem to be examined Formulate a specific problem statement to clearly define the problem Set measurable and attainable goals Identify stakeholders and develop necessary communication channels to communicate and gain approval Plan (Why) Divide overall system into individual processes - map the process Brainstorm potential causes for the problem Collect and analyze data to validate the root cause Formulate a hypothesis Verify or revise the original problem statement

Do Establish experimental success criteria Design experiment to test hypothesis Gain stakeholder approval and support for the chosen solution Implement the experiment/solution on a trial or pilot basis

Check Gather/analyze data on the solution Validate hypothesis

Act Identify systemic changes and training needs for full implementation Plan ongoing monitoring of the solution Continuous improvement Look other improvement opportunities

DMAIC Define, Measure, Analyze, Improve, Control Very structured Linked a project directly to financial benefits.

Check Lists for Potential Project What is the problem you are trying to address? What are the potential benefits of solving this problem? Will you be able to quantify these benefits in terms of cost savings, cost avoidance, or improved customer satisfaction if you solve this problem? Do you have the necessary support and commitment from management/ key stakeholders to solve this problem? Is the resolution of this problem achievable given your span of influence (i.e., is the scope of the project reasonable)?

Check Lists for Potential Project What key output variables are needed to measure project success? Do you have a capable system to measure each of these key output variables? What key process input variables are you going to examine to determine the root cause(s) of your problem? Do you have a capable system to measure each of these key input variables? Do you have the appropriate analytical resources (training, software) necessary to solve this problem?

Potential Project Waste = Project = Improvement Easy to understand Short term Big impact

Project Ideas Sales  Reduce the time required to enter orders  Improve the process for checking customer credit Customer Service  Reduce number of call transfer Shipping/Receiving  Improve documentation accuracy  Improve inspection process  Reduce inventory damage and loss Etc..