Supercharging DMAIC IT’S TIME TO USE THE POWER OF THE COLLECTIVE MIND

Supercharging DMAIC IT’S TIME TO USE THE POWER OF THE COLLECTIVE MIND

Supercharging DMAIC
IT’S TIME TO USE THE POWER OF THE
COLLECTIVE MIND
Traditional Lean Sigma Toolkit and Methodology-DMAIC
2
Phases
Reviews (tollgate meetings)
1.0
1.0
Define
Define Opportunities
Opportunities
1. Complete Project Charter
2.0
Measure
Performance
4. Identify what to measure
Tools:
 Charter:
- Business case
- Opportunity Statement/ Goal
Statement
 Project Scope
 Project Team, Project Plan
 Preliminary Problem
Statement
Tools:
 FMEA
 C&E Matrix
 Data Collection Plan
 Functional Process Map
 VA/ NVA Analysis
 Value Stream Mapping
 TAKT Analysis
2. Specify customer and
business requirements
Tools:
 VOC/ VOB
 Stakeholder Analysis
 CTQ Tree
 Kano Model
 Change Management
 Elevator Speech
3. Complete high level SIPOC
5. Plan and collect data
Tools:
 Block Diagram
 5S
 SIPOC
Quick Wins / *RIP/
Kaizen
Define Tollgate Sign-Off:
Contract between the sponsor
and team as to what they are
going to work on
3.0
Analyze Root
Causes
7. Refine problem statement
Tools:
 Fishbone Diagram
 Brainstorming
 Five Whys
 Value Stream Analysis
4.0
Improve
10. Generate, prioritize and
select solution ideas
Tools:
 Brainstorming
 5S
 Poka Yoke
 Rapid Setup
 Pull Systems
5.0
Control
Performance
13. Institutionalize
the solution
Tools:
 Change Management
 Stakeholder Analysis
 Process Capability
 Process Control Plan &
dashboard
 Signed off benefits
 Control Charts
14. Replicate and share best
practices
Tools:
 Project Database
 Lean Sigma Network
8. Rank key causes of
variation
Tools:
 Descriptive Statistics
 Stratification
 Graphical Analysis
 Value Stream Analysis
 FMEA
11. Validate impact of
solution(s)
Tools:
 Should be process map
 Cost/ Benefit Analysis
 Multi-voting
 Solution selection matrix
 FMEA
6. Determine process
baseline capability
9. Validate root causes
12. Develop full scale
implementation report
15. Celebrate
Tools:
 Process Capability
 Pareto
 Descriptive Statistics
 Control Chart
Tools:
 Graphical Analysis
 Pareto
Tools:
 Project Plan
 Pilot
 Solution implementation
report
 FMEA
Tools:
 Project Database
 Lean Sigma Network
 Celebrate
Engineer Tollgate Sign-Off:
Proposed solutions validated
and implemented
Control Tollgate Sign-Off:
Solutions institutionalized
and offered for replication
Tools:
 Data Collection Plan
 Operational definitions
 Measurement System
Analysis
 Sample Size
Quick Wins / RIP?
Quick Wins / RIP?
3
Supercharged DMAIC
Phases
Reviews (tollgate meetings)
1.01.0
Define
Define Opportunities
Opportunities
1. Complete Project Charter
2.0
Measure
Performance
4. Identify what to measure
3.0
Analyze Root
Causes
4.0
Improve &
Innovate
7. Refine problem
statement10. Generate, prioritize
and select solution ideas
Tools:
 Charter:
- Business case
- Opportunity Statement/ Goal
Statement
 Project Scope
 Project Team, Project Plan
 Preliminary Problem
Statement
Tools:
 FMEA
 C&E Matrix
 Data Collection Plan
 Functional Process Map
 VA/ NVA Analysis
 Value Stream Mapping
 TAKT Analysis
2. Specify customer and
business requirements
Tools:
 VOC/ VOB
 Stakeholder Analysis
 CTQ Tree
 Kano Model
 Change Management
 Elevator Speech
3. Complete high level
SIPOC and clean up
Tools:
 Block Diagram
 5S
 SIPOC
5. Plan and collect data
8. Rank key causes of
waste and variation
Tools:
 Data Collection Plan
 Operational definitions
 Measurement System
Analysis
 Sample Size Calculator
Tools:
 Descriptive Statistics
 Stratification
 Graphical Analysis
 Value Stream Analysis
 FMEA
6. Determine process
baseline capability
9. Validate root causes
Tools:
 Process Capability
 Pareto
 Descriptive Statistics
 Control Charts
Tools:
 Graphical Analysis
 Pareto
Quick Wins *RIP/
Kaizen?
Define Tollgate Sign-Off:
Contract between the sponsor
and team agreeing on project
scope and goals.
Quick Wins / RIP?
Tools:
 Fishbone Diagram
 Brainstorming
 Five Whys
 Value Stream Analysis
Quick Wins / RIP?
Tools:
 Brainstorming
 5S
 Poka Yoke
 Rapid Setup
 Pull Systems
11. Validate impact of
solution(s)
Tools:
 Should be process map
 Cost/ Benefit Analysis
 Multi-voting
 Solution selection matrix
 FMEA
12. Develop full scale
implementation plan and
execute
Tools:
 Project Plan
 Pilot
 Solution implementation
report
 FMEA
Engineer Tollgate Sign-Off:
Proposed solutions validated
and implemented
5.0
Control
Performance
13. Institutionalize
the solution
Tools:
 Change Management
 Stakeholder Analysis
 Process Capability
 Process Control Plan &
dashboard
 Signed off benefits
 Control Charts
14. Replicate and share
best practices
Tools:
 Project Database
Knowledge management
process
 Lean Sigma Network
15. Celebrate!
Tools:
 Project Database
 Lean Sigma Network
 Appropriate Cultural
Rewards and, or
Recognition
Control Tollgate Sign-Off:
Solutions institutionalized
and offered for replication