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Supercharging DMAIC

Supercharging DMAIC. IT’S TIME TO USE THE POWER OF THE COLLECTIVE MIND. Traditional Lean Sigma Toolkit and Methodology-DMAIC. Reviews (tollgate meetings). 1 .0 Define Opportunities. 2.0 Measure Performance. 5.0 Control Performance. 3.0 Analyze Root Causes. 4.0 Improve. 1.0

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Supercharging DMAIC

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

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

  3. The Power of Trained Individuals and Teams in Lean, 6S or Lean Six Sigma Competencies Readily Attained Thru a Variety of Modalities SuperchargedDMAIC Reviews (tollgate meetings) 5.0 Control Performance 4.0 Improve & Innovate 1.0 Define Opportunities 2.0 Measure Performance 3.0 Analyze Root Causes 1.0 Define Opportunities Phases 13. Institutionalize the solution 7. Refine problem statement 10. Generate, prioritize and select solution ideas 4. Identify what to measure 1. Complete Project Charter • 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 • Tools: • Brainstorming • 5S • Poka Yoke • Rapid Setup • Pull Systems • Tools: • Change Management • Stakeholder Analysis • Process Capability • Process Control Plan & dashboard • Signed off benefits • Control Charts • Tools: • Fishbone Diagram • Brainstorming • Five Whys • Value Stream Analysis 8. Rank key causes of waste and variation 2. Specify customer and business requirements 11. Validate impact of solution(s) 14. Replicate and share best practices 5. Plan and collect data Utilize Idea Management Methods and Idea/Innovation Technology Crowdsourcing & Communities of Practice = The Power of the Collective Mind! • Tools: • Should be process map • Cost/ Benefit Analysis • Multi-voting • Solution selection matrix • FMEA • Tools: • Project Database • Knowledge management process • Lean Sigma Network • Tools: • Data Collection Plan • Operational definitions • Measurement System Analysis • Sample Size Calculator • Tools: • VOC/ VOB • Stakeholder Analysis • CTQ Tree • Kano Model • Change Management • Elevator Speech • Tools: • Descriptive Statistics • Stratification • Graphical Analysis • Value Stream Analysis • FMEA 12. Develop full scale implementation plan and execute 6. Determine process baseline capability 9. Validate root causes 15. Celebrate! 3. Complete high level SIPOC and clean up • Tools: • Block Diagram • 5S • SIPOC • Tools: • Graphical Analysis • Pareto • Tools: • Project Database • Lean Sigma Network • Appropriate Cultural Rewards and, or Recognition • Tools: • Process Capability • Pareto • Descriptive Statistics • Control Charts • Tools: • Project Plan • Pilot • Solution implementation report • FMEA Quick Wins *RIP/ Kaizen? Quick Wins / RIP? Define Tollgate Sign-Off: Contract between the sponsor and team agreeing on project scope and goals. Quick Wins / RIP? Engineer Tollgate Sign-Off: Proposed solutions validated and implemented Control Tollgate Sign-Off: Solutions institutionalized and offered for replication

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