DMAIIC (DMAIC is a data-driven, problem)

Measure Phase in DMAIIC
➢ It is in the measure phase where performance of the project is
evaluated. It is about finding out the current performance and
compare it to the desired performance.
➢ It is in this phase where the team will obtain and begin to analyze
the data necessary to drive the project to completion or target.
TOTAL QUALITY MANAGEMENT
Measure Phase Tools
▪ Data Collection Plan
▪ Measurement System Analysis
▪ Process Capability Analysis
▪ In Scope/Out of Scope

▪ Data Collection Plan
➢ A plan for collecting data if data needed in the project is not available.
➢ In Six Sigma, it is detailed document outlining the steps and methods
needed to gather data
Sample Format of Data Collection Plan using Microsoft Word (in table form)
• Data Description
• Type of Data
• Criteria
• Measurement Point
• Sample Rate, and
• Data Collection Form

• Data Collection Form
➢ this is developed when there is no existing data
➢ In Six Sigma, it is a standardized document used to record
measurements and observations during the "Measure" phase of the
project
➢ the form should satisfy the following:
✓What data are to be collected (or what is to be measured or
observed)?
✓How will it be collected (tools, gages, fixtures, etc.)?
✓How often will it be collected (what point in the process and
condition)?
✓Where will it be recorded?

• Measurement System Analysis (or GR&R)
➢ GR&R stands for Gage Repeatability and Reproducibility
➢ it determines the amount of variation that exist in a measurement process.
➢ In Lean Six Sigma, MSA is a statistical tool used to assess the accuracy and
precision of a measurement system.
Sources of variation in measurement system includes the following:
o Bias in the gage (parallax error, meniscus error, etc.)
- above and below true values
o Repeatability (gage is not repeatable)
- show variation in measurement conducted by same operator
o Reproducibility
- pertains to the ability of a second operator to achieve the same result as
a previous operator working with the same equipment and under the
same condition (Sample Reason: Operators discretion in measurement

• Process Capability Analysis
➢ aid in setting specifications or support the prediction of scrap, rework, and
throughput.
➢ Use facts and data to eliminate variations from design to manufacture.
➢ It is a statistical method that compares how well a process meets its specifications.
The following are the steps to follow in process capability analysis:
1. Develop a comprehensive strategy. Prioritize your processes according to
highest loss (scrap, rework, cost, etc.) and start working on the highest ones
(the vital few).
2. Stabilize the process by removing sources of special cause variation (If the
process does not have SPC (Statistical Process Control), apply it and get the
process under statistical control, that is, predictable.
Note:
1. Statistical Process Control is a statistical method used to monitor and control the quality of a process or product.
2. Common causes of process shift are machine wear, incorrectly process set-up, new operators, changes in material batch, and
other issues.

• Process Capability Analysis
➢ aid in setting specifications or support the prediction of scrap, rework, and
throughput.
➢ Use facts and data to eliminate variations from design to manufacture.
The following are the steps to follow in process capability analysis:
3. Use existing data from a stable SPC process to assess capability. (from the
SPC chart, obtain estimates of the process average and standard deviation
and assess the process Cpk.
4. Determine the best approach for your business (based on the resulting Cpk,
determine whether to change the product specification or improve the
process using the DMAIIC process.
5. Move to the next process in the list
Note:
1. Capability Index Cpk indicates how much room there is between the product specification (tolerance) limits and the
expected output of the process.

• In-Scope / Out-of-Scope
➢ These are list or graphics forms (ex. Spreadsheet) reviewed periodically with the
sponsors and decisions can be recorded along with the date they are made.
➢ In scope refers to works and deliverables defined in the project, while out-of-
scope refers to tasks out of the project plan.
Analyze Phase in DMAIIC
➢ In project management, it is the part where the collected data are thoroughly
examined to identify and verify the root causes of a problem.
➢ The analyze phase is where you begin to evaluate the possible process values
that have influence on the product or process. This is the phase in setting the
values of x in the process after ycurrent and ydesired are determined.
Note:
1. The ycurrent and ydesired are evaluated during the measure phase.

Tools for Analyze Phase in DMAIIC
▪ Cause-and-Effect Diagram (Ishikawa or Fishbone Diagram)
➢ helps identify the potential sources of a problem
▪ Graphical Data Analysis
➢ helps understand patterns of correlated parameters
▪ Pareto Principle and Diagram
➢ a bar graph (from largest to smallest) used to analyze data about
frequency of problems in a process. It helps you decide where/what to
focus or prioritize to address the problem.
▪ Design of Experiments and Hypothesis Testing
➢ this involves simulation to predict the outcome by changing the variables.
▪ Regression Analysis
➢ a statistical method used estimate or examine the relationship or
connection between a dependent variable to a non-dependent variable/s

Cause-and-Effect Diagram (Ishikawa or Fishbone Diagram)

Graphical Data Analysis (Scatter Diagram) Graphical Data Analysis (Histogram)
❖ Graphical Data Analysis – a method used to analyze the information or visualize the pattern formed by plotting the data.
❖ Scatter Diagram (Scatter Plot) – a tool for analyzing the relationship between two variables, plotted in two axes where the pattern of their
intersecting points graphically show relationship patterns.
❖ Histogram - is a graphical representation of a grouped frequency distribution with continuous classes. It is an area diagram and can be defined as
a set of rectangles with bases along with the intervals between class boundaries and with areas proportional to frequencies in the corresponding
classes.

Pareto Chart One-Factor-At-A-Time (OFAAT) Random Experimentation
❖ Pareto Chart – a chart that contains both bar and line graph. The length of the bar represents the frequency of a certain variable or parameter
arranged in descending order while the line represents the cumulative total of the bar graph.
❖ OFAAT - is a method of designing experiments involving the testing of factors, or causes, one at a time instead of multiple factors
simultaneously.
❖ Random Experimentation – a well defined procedure that produces an observable outcome which could not be perfectly predicted in
advance.

One-Factor-At-A-Time (OFAAT)
O-F-A-A-T
Uses of OFAT
• used to identify and optimize critical process parameters
• help ensure that process development meets quality
standards
• help make informed decisions about how to optimize
processes
• can be used to identify the most critical causes of an effect

One-Factor-At-A-Time (OFAAT)
O-F-A-A-T
Significant Steps in OFAAT
• important factors should be identified
• variables that could possibly influence the outcome should be
determine
• set baseline conditions
• establish a starting point by setting all variables to a standard level
• vary one factor at a time
• adjust only one variable at a time while keeping all other factors
constant, observing the effect on the response variable
• analyze results
• evaluate the data from each individual factor variation to understand
its impact on the outcome
Note:
OFAAT is not limited only to three variables. Tab or tabulation is used if there are many variables to consider.

Improve/Innovate Phase in DMAIIC
➢ This is used to close the gap between ycurrent and ydesired after the analyze
phase.
Tools for Improve/Innovate Phase in DMAIIC
▪ Cost-Benefit Analysis (Cost/Benefit Ratio or Saving-Investment Ratio, SIR)
➢ In Cost-Benefit Analysis, the present value stream of net revenues is
calculated divided by the present value stream of investments. It is an
effective measure for comparing project alternatives with fluctuating
cash flows.
➢ It is an accepted procedure for making go/no-go decisions on
independent projects and for comparing mutually exclusive projects in
the public sector

𝐵/𝐶 =
𝑃𝑊 (𝐵𝑒𝑛𝑒𝑓𝑖𝑡𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑝𝑟𝑜𝑗𝑒𝑐𝑡)
𝑃𝑊 (𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑝𝑟𝑜𝑗𝑒𝑐𝑡)
𝐵/𝐶 =
𝑃𝑊 (𝐵)
𝐼 −𝑃𝑊 𝑀𝑉 +𝑃𝑊 (𝑂&𝑀)
(conventional formula)
𝐵/𝐶 =
𝑃𝑊 𝐵 −𝑃𝑊 (𝑂&𝑀)
𝐼 −𝑃𝑊 (𝑀𝑉)
(modified formula)
where: 𝑃𝑊 = present worth
𝐵 = benefits of the proposed projects
𝐼 = initial investment in the proposed project
𝑀𝑉 = market value at the end of useful life
𝑂&𝑀 = operating and maintenance costs of the proposed project
▪ Cost-Benefit Analysis (Cost/Benefit Ratio or Saving-Investment Ratio, SIR)

▪ Brainstorming
➢an activity formed to gather inputs and develop a solution to a
problem.
▪ Risk Management
➢identifying the potential risks brought about by the changes to
the process, suppliers, to how users interface to the revised
device, etc.
▪ Piloting the solution
➢this involves testing or dry-run. This allows the recognition and
handling of issues prior to adapting the new process.

▪ Validate Improvement
➢this involves repeating the process capability analysis after the
improvement has been introduced into the process from a pilot or
early test.
▪ Plan and Implement
➢this involves scheduled project tasks .
▪ Documentation
➢this involves focusing on critical or important items in the process.
▪ Change Management
➢this involves shifting from current state to future state.

Plan and Implement (Activity Network Diagram)
❖ Activity Network Diagram - a diagram of project activities using arrows and nodes showing the sequential relationships of activities. It is used
extensively in and is necessary for the identification of a project’s critical path. This sequence is known as the critical path, and completing these
steps successfully drives the success of the overall project.

Plan and Implement (Activity Network Diagram)
A. Excavate
B. Foundation
C. Frame
D. Electrical
E. Roof
F. Masonry
G. Interior
H. Exterior
I. Landscape
Ex. 2. Process of building a house.
❖ Activity Network Diagram - a diagram of project activities using arrows and nodes showing the sequential relationships of activities. It is used
extensively in and is necessary for the identification of a project’s critical path. This sequence is known as the critical path, and completing these
steps successfully drives the success of the overall project.

Documentation (CTQ or Critical to Quality flowdown)

Services CTQ Diagram (Courtesy: www.health.state.mn.us.com
Note;
1. The raw data used in the CTQ are from the collected feedback and expectations from customers about a product or service or the
VOC (Voice of the Customer)

Voice of the Customer (Courtesy: chisellabs.com)
Note;
1. The raw data used in the CTQ are from the collected feedback and expectations from customers about a product or service or the
VOC (Voice of the Customer)

Control Phase in DMAIIC
➢ after values for the critical process inputs are found, it is important
to maintain the improvements after moving to the next stage.
Tools for Control Phase in DMAIIC
▪ Control Plan
➢a work instruction for a process.
Key items:
• Process step or phase
• Order of actions (if sequence is critical)
• CTQ linkage (if any)
• Target setting

▪ Control Plan
➢a work instruction for a process.
Key items:
• Allowable range
• Calibrations needed
• Sampling plan (number of samples, what to measure, what
measurement tool to use, and how often to sample)
• MSA (Measurement Systems Analysis) for measurement tools
• Reaction plan (orderly shutdown)
• Safety measures and equipment

▪ Evaluating Results
➢this involves evaluating the results against the target value
after pilot and validation of the process is conducted.
▪ Monitoring
➢this involves watching the improvement using the control plan.
▪ Statistical Process Control (SPC)
➢this involves statistical method or technique applied to detects
problems or issues to improve the process.

DMAIIC (DMAIC is a data-driven, problem)

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