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
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