1. OPS/571 Operations Management
Six Sigma: DMAIC
OPS/571
Operations Management

2. Six Sigma: DMAIC DMAIC Objectives of DMAIC Understand the process
Eliminate errors
Remove slack
Reduce variation
Plan for continual improvement
A main method used is six sigma to improve processes is DMAIC
Measure
Performance
Analyze
Opportunity
Improve
Control
Define
Opportunities
DMAIC

3. Define: Define Opportunities

4. Six Sigma: DMAIC
Define
Opportunities
Measure
Performance
Analyze
Opportunity
Improve
Performance
Control
Performance
Objective Main Activities Tools/Techniques Key Deliverables
Control Chart
CCR
Identify improvement opportunity
Develop business processes
Define Customers & Stakeholders
Define critical customer requirements
Prepare team
Assessment
Employee responsibility alignment
Process mapping
Translate critical customer requirements
Assess baseline metrics
Define opportunities & measurable goals
Critical Customer Requirements
Team Charter
Action Plan
Process Maps
Team Charter
Process Map
Before starting, it is important to define opportunities for improvement based on specific inputs
There may be more opportunities to improve than resources so tradeoffs or prioritization may be required
Action Plan

5. Measure:
Define Opportunities

6. Six Sigma: DMAIC
Measure
Performance
Define
Opportunities
Analyze
Opportunity
Improve
Performance
Control
Performance
Objective Main Activities Tools/Techniques Key Deliverables
Process Chart
Histogram
CCR
Identify critical measures
Develop methods for collecting data
Establish baseline sigma (variation) for processes
Develop Measurement Plan
Plot and Analyze Data
Validate Measurements
Determine desired performance
Collect other performance items
Inputs: Process Variables
Outputs: Process Responses
Data Collection formats & plans
Define baseline performance
Check sheet
Process Map
In the measure performance phase, it is necessary to understand where the process is starting so improvements can be measured.
Develop measurement Plan includes
Operational definition
Identify process inputs
Process Map here will include identification of input/process/output/CCR
1.1
1.2
1.3
Action Plan

7. Analyze:
Analyze Opportunity

8. Six Sigma: DMAIC
Analyze
Opportunity
Define
Opportunities
Measure
Performance
Improve
Performance
Control
Performance
Objective Main Activities Tools/Techniques Key Deliverables
Control Chart
Histogram
Analyze Data
Histogram
Control charts
Pareto’s
Run charts
Scatter Plot
Identify root cause(s)
Identify potential solutions
Data Analysis
Statement of root cause
Potential solutions
Stratify and Analyze Data
Identify and Validate the Root Cause
Identify Potential Solutions
Cause & Effect
Fishbone Diagram
Analyzing involves the activities of getting to the root cause of the problem. There are several techniques listed here.
Machine
People
Methods
Materials
Scatter Plot

9. Improve:
Improve Performance

10. Six Sigma: DMAIC
Improve
Performance
Define
Opportunities
Measure
Performance
Analyze
Opportunity
Control
Performance
Objective Main Activities Tools/Techniques Key Deliverables
Cost Benefit
Identify solutions
Develop a Change
Management Plan
Communicate Improvement Strategy
Statement of Solution
Development of Action Plan
Communicate Message of Solution using:
Process Map(s)
Analysis Doc’s
Storyboard
Impact & Benefits
Evaluate and Select Solutions
Determine Solution Impacts & Benefits
Communicate solution to all Customers & Stakeholders
Cost:
Installation
Spares
Benefit:
Productivity Savings
Gantt Chart
Process Map 1
Task A
Finally, after all of this prep, we get to FIX SOMETHING.
This is the section where many non six sigma based improvement methods start.
However improvements starting without the DMA phases are often unsustainable or they “fix” only a portion of the problem 2
Task B 3
Task C
Force Field Analysis
Forces for idea
Forces against idea

11. Control:
Control Performance

12. Six Sigma: DMAIC
Control
Performance
Define
Opportunities
Measure
Performance
Analyze
Opportunity
Improve
Performance
Objective Main Activities Tools/Techniques Key Deliverables
Run Charts
Executive plan
Disseminate lessons learned
Institute new process
Determine other improvement opportunities.
Process control systems
Standards and procedures
Training
Change implementation plan
Continuous improvement document
Standardization
Develop pilot plan
Summarize experiences and lessons.
Develop institutionalization of plan
Identify continuous improvement opportunities.
Lessons
Learned 1
Poor X
Process Control 2
Late K 3
Late Y
After the fix, then what? The “fix” must be institutionalized so that it can be sustained.
What if the leader changes or what if there is a large turn-over of staff, can the improvement be sustained?
What if there is a change of computer systems, can the improvement be sustained?
Change Plans
CCR
GAP

13. Exercise: Matching Team-Check
Descriptive Statement or Question
Answer
Optimize the process or performance.
States the current performance level.
Identify opportunity that would provide the biggest business payoff.
Determine an operational definition that states the methodology to collect data and the amount of data to be collect
Customer surveys indicate a high level of customer dissatisfaction, which can be quantified as a cost or loss.
State how you can sustain the gains you have made.
Marketing studies have been distributed.
Disseminate lesson’s learned to ensure replication and standardization of performance improvements.
Find the inputs that are the largest contributors to the defective performance.
What is the best solution?
Determine root causes for the identified gaps in performance.
Define the priorities and establish the performance targets.
Process Model Step
1.0 Define Opportunities
2.0 Measure Performance
3.0 Analyze Opportunity
4.0 Improve Performance
5.0 Control Performance
Let’s see if you can identify what phase each of these activities fall into.

14. Exercise: Matching Team-Check Answer Key
Descriptive Statement or Question
Answer
Optimize the process or performance. 4
States the current performance level. 3
Identify opportunity that would provide the biggest business payoff. 1
Determine an operational definition that states the methodology to collect data and the amount of data to be collect 2
Customer surveys indicate a high level of customer dissatisfaction, which can be quantified as a cost or loss.
State how you can sustain the gains you have made. 5
Marketing studies have been distributed.
Disseminate lesson’s learned to ensure replication and standardization of performance improvements.
Find the inputs that are the largest contributors to the defective performance.
What is the best solution?
Determine root causes for the identified gaps in performance.
Define the priorities and establish the performance targets.
Process Model Step
1.0 Define Opportunities
2.0 Measure Performance
3.0 Analyze Opportunity
4.0 Improve Performance
5.0 Control Performance
And the answers are…