1. OPEX DMAIC Routemap Slides
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2. OPEX DMAIC Routemap Slide Permissions
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3. DMAIC – a logical flow to problem solving
An iterative approach
© OPEX Resources Ltd
From ‘Lean Six Sigma and Minitab’, ISBN
Define
the Problem
Measure
the Process
Analyse
Improve
Control
Gain project approval
Close the project

4. 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
From ‘Lean Six Sigma and Minitab’, ISBN

5. 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
From ‘Lean Six Sigma and Minitab’, ISBN

6. 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
From ‘Lean Six Sigma and Minitab’, ISBN

7. 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
From ‘Lean Six Sigma and Minitab’, ISBN

8. 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
From ‘Lean Six Sigma and Minitab’, ISBN

9. 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
From ‘Lean Six Sigma and Minitab’, ISBN

10. 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
From ‘Lean Six Sigma and Minitab’, ISBN

11. 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
From ‘Lean Six Sigma and Minitab’, ISBN

12. 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
From ‘Lean Six Sigma and Minitab’, ISBN

13. 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
From ‘Lean Six Sigma and Minitab’, ISBN

14. 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
From ‘Lean Six Sigma and Minitab’, ISBN

15. 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
From ‘Lean Six Sigma and Minitab’, ISBN

16. 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
From ‘Lean Six Sigma and Minitab’, ISBN

17. 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
From ‘Lean Six Sigma and Minitab’, ISBN

18. 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
From ‘Lean Six Sigma and Minitab’, ISBN

19. 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
From ‘Lean Six Sigma and Minitab’, ISBN

20. 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
From ‘Lean Six Sigma and Minitab’, ISBN

21. 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
From ‘Lean Six Sigma and Minitab’, ISBN

22. 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
From ‘Lean Six Sigma and Minitab’, ISBN

23. 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
From ‘Lean Six Sigma and Minitab’, ISBN

24. 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
From ‘Lean Six Sigma and Minitab’, ISBN

25. 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
From ‘Lean Six Sigma and Minitab’, ISBN

26. 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
From ‘Lean Six Sigma and Minitab’, ISBN

27. 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
From ‘Lean Six Sigma and Minitab’, ISBN

28. 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
From ‘Lean Six Sigma and Minitab’, ISBN

29. 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
From ‘Lean Six Sigma and Minitab’, ISBN

30. 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
From ‘Lean Six Sigma and Minitab’, ISBN

31. 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
From ‘Lean Six Sigma and Minitab’, ISBN

32. 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
From ‘Lean Six Sigma and Minitab’, ISBN

33. 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
From ‘Lean Six Sigma and Minitab’, ISBN

34. 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
From ‘Lean Six Sigma and Minitab’, ISBN

35. 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
From ‘Lean Six Sigma and Minitab’, ISBN

36. 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
From ‘Lean Six Sigma and Minitab’, ISBN

37. 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
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
From ‘Lean Six Sigma and Minitab’, ISBN
Good Bad

38. 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
From ‘Lean Six Sigma and Minitab’, ISBN

39. 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
From ‘Lean Six Sigma and Minitab’, ISBN

40. 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
From ‘Lean Six Sigma and Minitab’, ISBN

41. 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
From ‘Lean Six Sigma and Minitab’, ISBN

42. 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
From ‘Lean Six Sigma and Minitab’, ISBN

43. 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
From ‘Lean Six Sigma and Minitab’, ISBN

44. 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
From ‘Lean Six Sigma and Minitab’, ISBN