OPEX DMAIC Routemap Slides
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The use of these slides is subject to the conditions on slide 2.

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DMAIC – a logical flow to problem solving
An iterative approach
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
Define
the Problem
Measure
the Process
Analyse
the Process
Improve
the Process
Control
the Process
Gain project
approval
Close the
project

The flow of the Define Phase
Define Measure Analyse Improve Control
Define the
business case
Understand
the customer
Define the
process
Manage the
project
Gain project
approval
“To develop a clear project charter based on a real problem
that is relevant to the customer, and that will provide
significant benefits to the organisation.”
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Define Phase
Define Measure Analyse Improve Control
Define the
business case
Understand
the customer
Define the
process
Manage the
project
Gain project
approval
How does the
problem link to
the customer?
Are you clear which
process the problem
relates to?
Who? Where?
When? How?
What’s wrong?
What do you want
to achieve?
Does the project
have the buy-in
to proceed and
succeed?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Define Phase
Define Measure Analyse Improve Control
Define the
business case
Understand
the customer
Define the
process
Manage the
project
Gain project
approval
How does the
problem link to
the customer?
Are you clear which
process the problem
relates to?
Who? Where?
When? How?
What’s wrong?
What do you want
to achieve?
Does the project
have the buy-in
to proceed and
succeed?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Define Phase
Define Measure Analyse Improve Control
Define the
business case
Understand
the customer
Define the
process
Manage the
project
Gain project
approval
How does the
problem link to
the customer?
Are you clear which
process the problem
relates to?
Who? Where?
When? How?
What’s wrong?
What do you want
to achieve?
Does the project
have the buy-in
to proceed and
succeed?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Define Phase
Define Measure Analyse Improve Control
Define the
business case
Understand
the customer
Define the
process
Manage the
project
Gain project
approval
How does the
problem link to
the customer?
Are you clear which
process the problem
relates to?
Who? Where?
When? How?
What’s wrong?
What do you want
to achieve?
Does the project
have the buy-in
to proceed and
succeed?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Define Phase
Define Measure Analyse Improve Control
Define the
business case
Understand
the customer
Define the
process
Manage the
project
Gain project
approval
How does the
problem link to
the customer?
Are you clear which
process the problem
relates to?
Who? Where?
When? How?
What’s wrong?
What do you want
to achieve?
Does the project
have the buy-in
to proceed and
succeed?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Define Phase
Define Measure Analyse Improve Control
Define the
business case
Understand
the customer
Define the
process
Manage the
project
Gain project
approval
How does the
problem link to
the customer?
Are you clear which
process the problem
relates to?
Who? Where?
When? How?
What’s wrong?
What do you want
to achieve?
Does the project
have the buy-in
to proceed and
succeed?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Measure Phase
Define Measure Analyse Improve Control
Develop
process
measures
Collect
process data
Check the
data quality
Understand
process
behaviour
Baseline Process
capability &
potential
“To understand and baseline the current performance of the
process, through a set of relevant and robust measures (KPIs).”
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

When and where
does the data
come from?
Does the data
represent what you
think it does?
How does the
process currently
behave?
How do you
measure the
problem?
What is the current
performance of the
process with respect
to the customer?
Define Measure Analyse Improve Control
Develop
process
measures
Collect
process data
Check the
data quality
Understand
process
behaviour
Baseline Process
capability &
potential
The flow of the Measure Phase
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Measure Phase
Define Measure Analyse Improve Control
Develop
process
measures
Collect
process data
Check the
data quality
Understand
process
behaviour
Baseline Process
capability &
potential
When and where
does the data
come from?
Does the data
represent what you
think it does?
How does the
process currently
behave?
How do you
measure the
problem?
What is the current
performance of the
process with respect
to the customer?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Measure Phase
Define Measure Analyse Improve Control
Develop
process
measures
Collect
process data
Check the
data quality
Understand
process
behaviour
Baseline Process
capability &
potential
When and where
does the data
come from?
Does the data
represent what you
think it does?
How does the
process currently
behave?
How do you
measure the
problem?
What is the current
performance of the
process with respect
to the customer?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Measure Phase
Define Measure Analyse Improve Control
Develop
process
measures
Collect
process data
Check the
data quality
Understand
process
behaviour
Baseline Process
capability &
potential
When and where
does the data
come from?
Does the data
represent what you
think it does?
How does the
process currently
behave?
How do you
measure the
problem?
What is the current
performance of the
process with respect
to the customer?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Measure Phase
Define Measure Analyse Improve Control
Develop
process
measures
Collect
process data
Check the
data quality
Understand
process
behaviour
Baseline Process
capability &
potential
When and where
does the data
come from?
Does the data
represent what you
think it does?
How does the
process currently
behave?
How do you
measure the
problem?
What is the current
performance of the
process with respect
to the customer?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Measure Phase
Define Measure Analyse Improve Control
Develop
process
measures
Collect
process data
Check the
data quality
Understand
process
behaviour
Baseline Process
capability &
potential
When and where
does the data
come from?
Does the data
represent what you
think it does?
How does the
process currently
behave?
How do you
measure the
problem?
What is the current
performance of the
process with respect
to the customer?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase
Define Measure Analyse Improve Control
Analyse the
process
Develop theories
and ideas (possible
root causes)
Analyse
the data
Verify root causes
and understand
cause and effect
“To find the root causes of the problem, and
understand/quantify their effect on process performance.”
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase
Define Measure Analyse Improve Control
What does the
existing process
knowledge say?
What does the
data say?
How does the root
cause affect the
process output?
How does the process
actually work?
Analyse the
process
Develop theories
and ideas (possible
root causes)
Analyse
the data
Verify root causes
and understand
cause and effect
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase
Define Measure Analyse Improve Control
Analyse the
process
Develop theories
and ideas (possible
root causes)
Analyse
the data
Verify root causes
and understand
cause and effect
What does the
existing process
knowledge say?
What does the
data say?
How does the root
cause affect the
process output?
How does the process
actually work?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase
Define Measure Analyse Improve Control
Analyse the
process
Develop theories
and ideas (possible
root causes)
Analyse
the data
Verify root causes
and understand
cause and effect
What does the
existing process
knowledge say?
What does the
data say?
How does the root
cause affect the
process output?
How does the process
actually work?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase
Define Measure Analyse Improve Control
Analyse the
process
Develop theories
and ideas (possible
root causes)
Analyse
the data
Verify root causes
and understand
cause and effect
What does the
existing process
knowledge say?
What does the
data say?
How does the root
cause affect the
process output?
How does the process
actually work?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase
Define Measure Analyse Improve Control
Analyse the
process
Develop theories
and ideas (possible
root causes)
Analyse
the data
Verify root causes
and understand
cause and effect
What does the
existing process
knowledge say?
What does the
data say?
How does the root
cause affect the
process output?
How does the process
actually work?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase
Define Measure Analyse Improve Control
Generate
potential solutions
Select the
best solutions
Assess the risks Pilot and implement
“To develop, select and implement the best solutions,
with controlled risks.”
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase
Which solutions
are most likely to
work?
What are the risks
of implementing
the solutions?
When, where and how
will the solutions be
implemented?
What are all the
different possible
solutions?
Define Measure Analyse Improve Control
Generate
potential solutions
Select the
best solutions
Assess the risks Pilot and implement
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase
Define Measure Analyse Improve Control
Generate
potential solutions
Select the
best solutions
Assess the risks Pilot and implement
Which solutions
are most likely to
work?
What are the risks
of implementing
the solutions?
When, where and how
will the solutions be
implemented?
What are all the
different possible
solutions?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase
Define Measure Analyse Improve Control
Generate
potential solutions
Select the
best solutions
Assess the risks Pilot and implement
Which solutions
are most likely to
work?
What are the risks
of implementing
the solutions?
When, where and how
will the solutions be
implemented?
What are all the
different possible
solutions?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase
Define Measure Analyse Improve Control
Generate
potential solutions
Select the
best solutions
Assess the risks Pilot and implement
Which solutions
are most likely to
work?
What are the risks
of implementing
the solutions?
When, where and how
will the solutions be
implemented?
What are all the
different possible
solutions?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase
Define Measure Analyse Improve Control
Generate
potential solutions
Select the
best solutions
Assess the risks Pilot and implement
Which solutions
are most likely to
work?
What are the risks
of implementing
the solutions?
When, where and how
will the solutions be
implemented?
What are all the
different possible
solutions?
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase
Define Measure Analyse Improve Control
Implement ongoing
measurement
Standardise
the solutions
Quantify the
improvement
Close the project
“To ensure the solutions are embedded, the process has
robust controls, and the project has clear closure.”
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase
Have the changes
become ‘business
as usual‘?
Has the project goal
been achieved?
Does the project
have a clear
closure process?
How will the process
be measured after
the project?
Define Measure Analyse Improve Control
Implement ongoing
measurement
Standardise
the solutions
Quantify the
improvement
Close the project
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase
Have the changes
become ‘business
as usual‘?
Has the project goal
been achieved?
Does the project
have a clear
closure process?
How will the process
be measured after
the project?
Define Measure Analyse Improve Control
Implement ongoing
measurement
Standardise
the solutions
Quantify the
improvement
Close the project
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase
Have the changes
become ‘business
as usual‘?
Has the project goal
been achieved?
Does the project
have a clear
closure process?
How will the process
be measured after
the project?
Define Measure Analyse Improve Control
Implement ongoing
measurement
Standardise
the solutions
Quantify the
improvement
Close the project
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase
Have the changes
become ‘business
as usual‘?
Has the project goal
been achieved?
Does the project
have a clear
closure process?
How will the process
be measured after
the project?
Define Measure Analyse Improve Control
Implement ongoing
measurement
Standardise
the solutions
Quantify the
improvement
Close the project
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase
Have the changes
become ‘business
as usual‘?
Has the project goal
been achieved?
Does the project
have a clear
closure process?
How will the process
be measured after
the project?
Define Measure Analyse Improve Control
Implement ongoing
measurement
Standardise
the solutions
Quantify the
improvement
Close the project
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Measurement System Analysis Routemap
Start here
No
Is the level
of precision
acceptable?
Is the level of
bias (accuracy)
acceptable?
Is the resolution
acceptable?
Yes
Yes
Yes
No
No
Gage R&R Study
Attribute GR&R Study
MSA Drilldown
Attribute GR&R – with a known
standard
MSA Drilldown
Rule of tens
Minitab’s ‘number of
distinct categories’
The tools for assessing the
measurement system…
Same as above, plus:
Develop operating procedures for use of
measurement system, and train users.
Ensure measurement system is fit for purpose.
Calibrate the measurement system.
Improve/communicate the operational definition.
Redesign measurement system to reflect the
operational definition.
Check for rounding during data collection.
Use full resolution of measurement system.
Improve resolution of measurement system
(upgrade or replace equipment or system).
Possible actions for improving the
measurement system…
Move on with the project!
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Process Capability Routemap
Calculate the
% Defective
Clarify if your % defective
is short or long term
Convert into a
Sigma Level
Calculate
Sigma Shift
Continuous Data
Attribute Data
Short
Term
Metrics
Long
Term
Metrics
%ST
%LT
PPM
DPMO
ZST
ZLT
Sigma
Shift
Count Data
ZSHIFT
You can use the PPM or DPMO metrics to present the %
defective in the long term.
Short
Term
Long
Term
LSL USL
Defects
Good
Bad
0 1 2 3
Good Bad
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The Process Door Routemap
Getting to know the process as it
actually happens…
- Process Mapping & Value Stream Mapping
- Time Value Maps and Value Add Charts
- Seven Wastes and Spaghetti Diagrams
Assessing what could go wrong and where…
- Failure Mode and Effects Analysis (FMEA)
Understanding what does go wrong in the
process and where…
- Affinity Diagrams
- Measles Charts
Identifying possible root causes…
- Brainstorming
Structure possible root causes in a logical
manner…
- Fishbone (Cause and Effect) Diagrams
Investigate a defect to understand its root
cause…
- 5 Whys
Understand which process inputs are critical
to customer requirements…
- Cause and Effect Matrix
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The Data Door Routemap
Looking at distributions…
- Histogram, Dot Plot
- Minitab’s Graphical Summary
- Probability Plot
Comparing distributions or groups of data…
- Box Plots and Individual Value Plots
- Multi-Vari Chart
Comparing proportions and percentages…
- 100% Stacked Bar Chart
Looking at different categories of data…
- Pareto Chart
Looking for relationships between data sets…
- Scatter Plot, Matrix Plot
- Bubble Plot
Deciding if data fits a particular model…
- Normality Test (Anderson Darling)
- Individual Distribution Identification
Deciding if groups of data are different, and
quantifying the difference…
- Confidence Intervals
- Hypothesis testing
Quantifying the relationships between process
inputs and outputs…
- Correlation & Regression
- Simple Regression, Fitted Line Plot,
- Multiple Regression, Binary Logistic Regression
Adjusting the process to look for relationships
between its inputs and outputs…
- Design of Experiments (DOE)
Looking for changes over time…
- Time Series Plot, Trend Analysis
Deciding if changes over time are significant…
- Statistical Process Control (SPC)
- Run Charts
For graphical analysis… For statistical analysis…
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Hypothesis Tests for Averages
or
No
Are the samples Normally
distributed ?
You want to compare the averages of
some samples of data to decide if
they are statistically different.
You could try transforming the data
using Data Transformation.
You could compare the median
values of the samples instead.
How many samples do
you want to compare ?
1 Sample t-Test
For comparing the average of one
sample against a specific target or
historical average.
Yes OR
One Two Three or more
Start here:
Tukey’s Quick Test
For comparing the averages
of two samples.
2 Sample t-Test
For comparing the averages of two
samples against each other.
One Way ANOVA
For comparing the averages of three
or more samples against each other.
Paired t-Test
For comparing the averages of two
samples that are linked in pairs.
Not sure
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Hypothesis Tests for Medians
Yes
Yes Are the samples
Normally distributed?
You want to compare the medians of some
samples of data to decide if they are
‘statistically’ different.
How many samples do
you want to compare?
No
One Two or more
Don’t forget that you
can also test for
differences in average.
Are there any obvious
outliers in your samples?
No
Kruskal-Wallis Test
For comparing the medians of two
or more samples (with no outliers)
against each other.
Mood’s Median Test
For comparing the medians of two
or more samples (that have
outliers) against each other.
1 Sample Sign Test
For comparing the median of
one sample against a specific
target or historical average.
Start here:
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Hypothesis Tests for Standard Deviation
You want to compare the standard deviation
of some samples of data to decide if their
variation is statistically different.
How many samples do you
want to compare?
Levene’s Test
For comparing the standard
deviations of two or more samples
that are not Normally distributed.
Are the samples
Normally distributed?
F-Test
For comparing the standard
deviations of two samples that
are Normally distributed.
Bartlett’s Test
For comparing the standard
deviations of three or more
samples that are Normally
distributed.
Two
No Yes
Three or more
Start here:
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Types of Data
Numerical
Defined Categories
Age groups
Eye Colour
Data
Discrete
Counted Items
Defects per hour
Num. of Machines
Continuous
Measured Characteristics
Length, Weight,
Tensile Strength
Start here:
Categorical
Categorical data, as the name implies, are usually grouped into a
category or multiple categories

Hypothesis Tests for Proportions
You want to compare the proportions or percentages of different
samples of data to decide if they are statistically different.
How many proportions do
you want to compare ?
1 Proportion Test
For comparing a proportion
against a specific target or
historical proportion.
2 Proportions Test
For comparing two proportions
against each other.
Chi-Square Test
For comparing three or more
proportions against each other.
One Two Three or more
Start here:
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Statistical Process Control - Routemap
Is the data in
individuals or in
rational subgroups?
P Chart
For analysing proportions
or percentages.
I-MR Chart
For analysing individual
data points
X Bar–R Chart
For analysing the averages of
small subgroups (2-9).
X Bar-S Chart
For analysing the average of
large subgroups (more than 10).
U Chart
For analysing the Count or
Defects per Unit (DPU)
Subgroups
OR
Individuals
Continuous Count Attribute
Start here:
Laney U’ Chart
For analysing Counts or
Defects per Unit with
larger samples
Laney P’ Chart
For analysing proportions
or percentages with
larger samples.
Or Or
© OPEX Resources Ltd. 2004-2019
From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906
What type of data do you have?