BOM DMAIC TEMPLATE

www.bomconsultingg.com
bomconsulting@gmail.com
8 horas
FORMATO DMAIC

Description of the problem (what? where? since when? based on which data?
Based on which facts?)
Voice Of Customer (Customer perception)
Internal perception
Competitors benchmark
1 Pb Statement
Business Problem
Develop Goal statement/opportunity or objective in clear, concise, measurable terms
Demonstrate alignment of the project with the company/business strategy
2 Goal Statement
Define

Why to do the project?
What if project not done?
Financial Business Case
Business Case
3 Business Case
What Comment Cost
K€
Project Labor
Project Materials
Project Contractors
Equipment investment
Yearly operation cost
TOTAL Costs 0
Incremental Revenues
Labor Savings
Material Savings
TOTAL Benefits (1 year) 0
ROI 0
Define

Green Belt/Black Belt role:
Team members/role:
Black Belt:
Master Black Belt:
VP Quality / Quality Manager:
Manager:
Key stakeholders from Business team:
Customers:
Others:
4 Project scope
Project: in scope
D M A I C
Dates:
Gantt
Project: out of scope
Project charter
5 Team
6 Planning
Define

7 (SIPOC)
Process map & CTQ’s
process as felt by the customer
Input Output
Supplier =
My Company
Definition Specification Performance
limit targets
CTQ*
Step 2Step 1 Step 3
measurement
*Critical To Quality
My Customer
Define

M-step 1:
Selected CTQs
Selected Project CTQ(s):
Discrete/continuous CTQ?
CTQ Operational Definition(s):
What is it (measurement starting point and end point) ?
How to measure it?
What is a defect?
If applicable to your CTQ, LSL* contractual value or limit defined by customer:
If applicable to your CTQ USL* contractual value or limit defined by customer:
M-step 2:
Define
Performance
standard
Measure
CTQ details
*LSL Lower Specification Limit
*USL Upper Specification Limit

M-step 3:
Measurement
System Analysis
Measurement system analysis
Data Collection plan for Repeatability & Reproductibility study:
Data sample size =
Date of data collection:
Where data have been collected?
How data have been collected?
How many operators? How many repeats per operator?
Gage R&R study – Continuous data:
-Tolerance (USL-LSL):
-Short method (yes/no):
-Gage R&R as %contribution: Gage R&R as %tolerance: Nb of distinct categories:
Gage R&R study – discrete data:
If we have a Known sample (a reference), then how was built the known sample?
Conclusion/decision taken (evidence that the measurement of our CTQ is reliable):
Measure
Gage R&R

M-step 4:
Baseline current
(As Is) process
capability
CTQ data collection plan
•Data sample size =
•Date of data collection:
•Where data have been collected?
•How data have been collected?
•Will you take the opportunity to collect obvious X’s when collecting your CTQ measurements?
•If yes, which X’s:
•Display an extract of the data collected:
Measure
CTQ data collection plan

Continuous CTQ
•Sample size=
•Short term data or Long term data?
•Histogram with Normality test result and descriptive statistics:
•Type of the distribution (normal, other):
•Trend represented by its (m, median, Q1, Q3, other):
•Variability represented by its (s, P95, Q1/Q3, other):
PROCESS CAPABILITY MEASURE:
NORMAL Distribution
Observed DPMO=
Potential DPMO=
ZLT =
ZST (ZLT+1.5)=
Conclusion
•Problem with trend, variability or both?
M-step 4:
Baseline current
(As Is) process
capability
Photography of current performance
Measure
Non NORMAL Distribution
Observed DPMO=
Equivalent ZLT=
Equivalent ZST (ZLT+1.5)=

Discrete CTQ
•Sample size:
•Process capability
•Yield (%)=
•%defects=
•DPMO=
•Opportunities per unit=
•DPU=
•Equivalent ZLT=
•Equivalent ZST (ZLT+1.5)=
•95% confidence interval on DPMO:
Measure
Photography of current performance
M-step 4:
Baseline current
(As Is) process
capability

Continuous CTQ
•Normal probability plot:
Conclusion (can we detect a true process and an unstable process?):
All type of CTQ
•Stability over time/Run chart:
Conclusion:
•Pb of technology (short term common causes)?
•Pb of control (long term shift due to special causes)?
•Both pbs?
A-step 5:
As Is process
Graph Analysis
Analyze
Graph analysis

A-step 6: Define
Performance
Objectives of To
Be process
Improvement Goal
Target (from benchmark) for:
Trend:
Variability:
LT DPMO or LT %defects=
Yield (%)=
ZLT=
ZST=(ZLT+1.5)=
Gap (Improvement – Actual)
DPMO gap or Defect reduction factor:
Z gap=
6 Sigma tools necessary to meet performance objectives:
• Ground fruit: Logic and Intuition
• Low hanging fruit: Basic tools (Process Map, CE/CNX fishbone diagram, SOP, FMEA, Pareto,
Histogram, Box plot)
• Bulk of Fruit Process Characterization and Optimization
• Sweet Fruit: Transform the project into a DFSS project
Analyze
Set expected performance

A-step 7: Identify
X’s (root causes)
Process (AS IS) detail analysis:
•Detailed process map
Conclusion
•CTQ Intermediate distribution plot (continuous CTQ only)
Conclusion
Standard Operation Procedures analysis:
•Exist:
•Are applied:
•Incitation to apply them exist:
•Training has been given to operators:
Policy analysis:
•Exist
•Are applied
Analyze
Process analysis

List of potential significant X’s
Y/CTQ Output
Men
Machines
Materials
Methods
Measurements
Environment
Fishbone diagram of my Y
Label C/N/X on your fishbone, then rate every X impact vs implementation (table below)
Analyze
Potential root causes
A-step 7: Identify
X’s (root causes)

Results of segmentation (continuous CTQ only) :
(Box plots, Scatter plots, Distributions per X)
Conclusion:
Analyze
Segmentation analysis
A-step 7: Identify
X’s (root causes)

Pareto chart of the CTQ categories:
Conclusion:
Pareto chart of the defect categories:
Conclusion:
FMEA:
Conclusion:
Analyze
Pareto analysis
A-step 7: Identify
X’s (root causes)

Statistical Tests Performed
Test X Factors p value %contributionconclusion
one sample or two sample T-test
Annova one way
Homogeneity of variance
Chi square test
Simple regression
Non parametric data test
ANOVA 2 ways
GLM
DOE screening
Conclusion/Prioritized list of significant X’s:
Financial benefits confirmation (Update your Business case):
Analyze
Hypothesis testing
A-step 7: Identify
X’s (root causes)

I-step 8:
Screen potential
causes.
List improvement
actions/projects
List of Vital few Xs (screening DOE): Improvement action plan (Who What When):
Improve
Improvement actions

I13
X tolerance settings:
I-step 9: Discover
Variable
relationships
(if necessary)
Transfer function:
Proposed Solution: Optimal Settings
Confirmation runs capability:
I-step 10:
Establish
Operating
Tolerances
(if necessary)
Improve
Improved performance

Control
Gage R&R on X’s
C-step 11:
Define and
Validate
Measurement
System on X’s
(if necessary)
Control on one X (yes/no):
If yes, X measurement system analysis:
•Data Collection plan for Repeatability & Reproductibility study:
Data sample size =
Date of data collection:
Where data have been collected?
How data have been collected?
How many operators? How many repeats per operator?
•Gage R&R study – Continuous data:
-Tolerance (USL-LSL):
-Short method (yes/no):
-Gage R&R as %contribution: Gage R&R as %tolerance: Nb of distinct categories:
•Gage R&R study – discrete data:
If we have a Known sample (a reference), then how was built the known sample?
•Conclusion/decision taken (evidence that the measurement of our X is reliable):

C-step 12:
Determine new
Process Capability
Process or Product new capability:
Continuous CTQ:
NORMAL Distribution
Observed DPMO=
Potential DPMO=
ZLT =
ZST (ZLT+1.5)=
Discrete CTQ:
•Sample size:=
•Process capability
•Yield (%)=
•%defects=
•DPMO=
•Opportunities per unit=
•DPU=
•Equivalent ZLT=
•Equivalent ZST (ZLT+1.5)=
•95% confidence interval on DPMO
Statistical Confirmation of Improvement (by statistical test):
Confirmation of improved performance
Control
Non NORMAL Distribution
Observed DPMO=
Equivalent ZLT=
Equivalent ZST (ZLT+1.5)=

C-step 13:
Implement
Process Control
Control Charts (SPC) in place/review mechanisms:
Mistake Proofing action taken:
FMEA control actions in place:
Process controls
Control

MUCHAS GRACIAS!!
Agradecemos su interés en los Servicios de BOM Consulting Group
y esperamos poder apoyar cualquier tipo de iniciativa Lean que se
encuentre emprendiendo.
Para mayor información:
Página Web: http://www.bomconsultingg.com
Mail: bomconsulting@gmail.com
Teléfonos: Bogotá, Colombia
Oficina: Calle 66 No. 11 – 50 Of. 404
Celulares: (+57) 301 4305276
(+57) 3015029279
DESCARGA ESTA PRESENTACIÓN GRATIS EN NUESTRA
PÁGINA WEB !!

BOM DMAIC TEMPLATE

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