DMAIC-Six sigma process Improvement Approach


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DMAIC-Six sigma process Improvement Approach

  1. 1. Boutique product development company It is amazing what you can accomplish when you have a client-centric team to deliver outstanding products.
  2. 2. Six Sigma DMAIC Maryam Rehmat | Process Engineer. Arooj Un Nisa | Process Engineer. Boutique product development company It is amazing what you can accomplish when you have a client-centric team to deliver outstanding products.
  3. 3. Process Improvement begins with ‘‘Thinking Big’’ and ‘‘Starting Small’’ If it can’t be thought, it can’t be done. Six Sigma-Process Improvement Approach  Six Sigma Introduction  DMAIC  Key activities in DMAIC phases  Simobo-Case study Maryam Rehmat Process Engg.
  4. 4. Six Sigma –Process Improvement Approach Introduction to Six Sigma What is Six Sigma? Six Sigma is a proven, data-driven suite of improvement methodologies based on a common philosophy supported by measurement and tools for process and product Improvement. Maryam Rehmat Process Engg.
  5. 5. Philosophy Behind Six sigma philosophy states that defects can be eliminated by reducing variations. Reduced variations mean: • Improved Customer satisfaction • Reduced operating costs • Increased profitability Maryam Rehmat Process Engg.
  6. 6. Sigma Level It is, where a process or product performance falls when compared to customer specification. Table of levels with DPMO Maryam Rehmat Process Engg.
  7. 7. Primary Goals of Six Sigma The quest to reduce variation consists of two primary goals to be achieved in the following sequence: 1. Reduce Spread: Increase process precision or reduce variation 2. Center the process: Increase process accuracy Maryam Rehmat Process Engg.
  8. 8. Improvement Methodologies Six Sigma DMAIC DFSS LSS  DMAIC: for process improvement by reducing process variation and defects.  Design for Six Sigma: for designing new processes and products  Lean Six Sigma: for improving process efficiency and speed. Maryam Rehmat Process Engg.
  9. 9. What is DMAIC? A problem solving method that is a roadmap which can be used for any projects or quality improvements that needs to be made. Maryam Rehmat Process Engg.
  10. 10. Why DMAIC? This methodology should be used when a product or process is in existence at your company but is not meeting customer specification or is not performing adequately. Maryam Rehmat Process Engg.
  11. 11. Question arises: Why is DMAIC suitable for our environment? Because: We have processes BUT don’t know how are we doing with’em So, We want to know, Are we meeting our customer specifications? If YES then to what extent ? Where do our processes lay? Maryam Rehmat Process Engg.
  12. 12. What are DMAIC phases ? Maryam Rehmat Process Engg.
  13. 13. D- DEFINE THE PROBLEM. The Define Phase is the first phase of the Six Sigma improvement process. In this phase, the leaders of the project create a Project Charter, create a high-level view of the process, and begin to understand the needs of the customers of the process. Maryam Rehmat Process Engg.
  14. 14. MEASURE- MAP OUT THE CURRENT PROBLEM In the Measure Phase, the team focuses on data collection. They have two goals: • Determine the start point or baseline of the process and • Find clues to understand the root cause of the problem in the process. Maryam Rehmat Process Engg.
  15. 15. ANALYSE-IDENTIFY THE CAUSE OF THE PROBLEM In the Analyze Phase, data collected during the Measure Phase is reviewed. Both the data and the process are analysed, in an effort to narrow down and verify the root causes of waste and defects. Maryam Rehmat Process Engg.
  16. 16. IMPROVE- IMPLEMENT AND VERIFY THE SOLUTION In the Improve Phase, the team moves on to solution development. A structured improvement effort can lead to innovative and elegant solutions. Maryam Rehmat Process Engg.
  17. 17. CONTROL- MAINTAIN THE SOLUTION In the Control Phase, the team begins to document exactly how they want to sustain improvements by passing process improvement infrastructure on to the employees who work within the process. Maryam Rehmat Process Engg.
  18. 18. DMAIC Overview and Simobo Case Study Demonstration Arooj Un Nisa Process Engg.
  19. 19. D Key activities in the Define phase are: Define the problem statement or improvement opportunity in a way that effectively articulates why the Six Sigma project is necessary and why it is necessary right now.  Develop the project charter.  Map the current process.  Gather the voice of the customer (VOC).  Form the project team. Arooj Un Nisa Process Engg.
  20. 20. M Key activities in the Measure phase are:  Identify the measurements to collect  Develop and execute the measurements collection plan  Develop and validate the measurement system  Identify baseline performance measurements DPMO and sigma level Arooj Un Nisa Process Engg.
  21. 21. A Key activities in the Analyze phase are:  Stratify data to identify the underlying problem(s).  Identify root causes.  Validate root causes. Arooj Un Nisa Process Engg.
  22. 22. I Key activities in the Improve phase include the following:  Identify potential solutions.  Evaluate and select potential solutions. Arooj Un Nisa Process Engg.
  23. 23. C Key activities in Control phase include the following:  Pilot potential solutions (if needed).  Evaluate pilot results (if applicable).  Develop the control plan.  Develop the change implementation plan.  Develop procedures, standards, and training material.  Deliver training.  Communicate improvements.  Implement improvements. Arooj Un Nisa Process Engg.
  24. 24. Define Phase Activities performed on Simobo PROJECT CHARTER TITLE Managing and Enhancing Quality of our Product Simobo by reducing the number of support issues and non-conformities. BUSINESS CASE The IT industries have a lot of work in their domain but the satisfied customers are achieved only by High Quality Products This can only be achieved by o Increased Quality Service Time o Reducing Cost (Development and Maintenance) PROBLEM STATEMENT Confiz Solutions is committed to provide cost effective and efficient solutions to their customers. This can be achieved by Enhancing Quality of Simobo by reducing the number of support issues and non-conformities OBJECTIVES Reduction in Number of Support Issues and Defects METRICES Correctness, which is measured by Defect Density Defect Density = (number of Defects/size of product in LOC ) * 100 SCOPE Development and maintenance of Simobo. PROJECT SCHEDULE o o o o o Define Phase Measure Phase Analyze Phase Improve Phase Control Phase PROJECT MEMBERS o o Maryam Rehmat Arooj Un Nisa
  25. 25. SIPOC Supplier input process output customer      1. Domain Ramp up 2. Requirement Analysis 3. Insight to Design specifications 4. UI Testing 5. Functional testing 6. Integration testing 7. Defect logging 8. Defect verification 9. Defect closing 10. Defect responding      Development team Design team QA team I.T team    Client Requirements Design specifications PSD’S Code Defects/Bugs Build Status Report Features Developer I.T team
  26. 26. KPI’S AND KPO’S KEY PROCESS INPUTS KEY PROCESS OUTPUTS Qualification Defect Density Experience Bugs LOC Arooj Un Nisa Process Engg.
  27. 27. MEASURE PHASE-PARETO CHART Arooj Un Nisa Process Engg.
  28. 28. CAUSE AND EFFECT DIAGRAM Arooj Un Nisa Process Engg.
  29. 29. HISTOGRAM Arooj Un Nisa Process Engg.
  30. 30. PROBABILITY PLOT Arooj Un Nisa Process Engg.
  31. 31. CURRENT SIGMA LEVEL Arooj Un Nisa Process Engg.
  32. 32. Process Capability Arooj Un Nisa Process Engg.
  33. 33. ANALYSE PHASE TESTING OF HYPOTHESIS Our company is facing some support issues and we want to decrease these support issues to 5% so for this we have to hypothesize: Null Hypothesis: Support issues are >=5%. Alternate hypothesis: Support issues are< 5%. Arooj Un Nisa Process Engg.
  34. 34. IMPROVE PHASE DESIGN OF EXPERIMENTS Arooj Un Nisa Process Engg.
  35. 35. Arooj Un Nisa Process Engg.
  36. 36. Arooj Un Nisa Process Engg.
  37. 37. CONTROL PHASE FMEA (Failure Mode and Effect Analysis) Potential Failure Effect SEV Potential Causes OCC Current Controls DET RPN Actions recommended Resp. Missing features Poor quality app 10 Wrong time estimates 1 Increased no of resources 0 0 Add cushion time in estimates, Start domain ramp up at requirement elicitation phase Usman Missing requirements Design is not according to requirements 6 Negligence, No Requirement documentation 1 Increased no of resources 0 0 Involve QA at this stage Document requirements properly Aymen No traceability of requirements Cosmetic defects in App 9 PSD’s not provided/overlooked 1 Requirements mapped manually 0 0 Make sure to provide PSD’s in domain ramp up Aymen Incomplete elements exploration Poor user interface with low usability 8 Negligence Test scenarios missing 2 Reviews by mentors 1 16 Trainings Aymen Incomplete Requirement Analysis Non confirming products 10 Time bounds Neglecting Requirements/feature 1 Increased resources Reviews by mentors 2 20 Prepare Requirement traceability matrix Aymen Incomplete product Customer dis-satisfaction 10 Incomplete domain ramp up/feature exploration 2 Increased resources 3 60 Prepare Sanity checklist Aymen Defects not logged/ Ambiguous Description Incomplete fixation 5 Lack of training/communication issues 1 Unit testing Increase resources 0 0 Comm. Skills Training Aymen Ripple effect/ regression testing missing Bugs in App 8 Negligence No time for Halo testing 1 Cross check by other resource Increased resources 0 0 Correct estimates for testing of a sprint/build Aymen Closed without verification defective product 9 Time bounds Negligence 1 Verification by Pm 0 0 Review after build or sprint Aymen Reopened without verification Development overhead resource wastage 6 Incomplete testing Misunderstanding 1 Verification by Pm and Unit testing by Dev. 0 0 Review after build Aymen Defect Reopening Defect closing Defect Verification Defect logging Integration Testing Functional Testing UI Testing Insight to Design Specificatio ns Requirement Analysis Domain Ramp up Process Step Potential Failure Mode
  38. 38. Arooj Un Nisa Process Engg.
  39. 39. Arooj Un Nisa Process Engg.
  40. 40. Little Cast-Sigma Level Defects 284 Opportunities Total Units 7 8445 DPU 0.033629366 DPO DPMO Yeild 0.0048042 4804.195 0.9951958 Sigma Level 4.089612921 Arooj Un Nisa Process Engg.
  41. 41. Thank You !