By Adding “Features” - Improve and Innovate
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Transcript By Adding “Features” - Improve and Innovate
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