This document outlines the steps in a Six Sigma DMAIC process improvement project. It includes defining the problem and critical metrics, measuring current performance, analyzing processes and measurements, improving the processes, and controlling future performance. Key steps are defining critical metrics, establishing baselines, determining root causes, piloting solutions, creating control systems, and finalizing documentation.

1. 15 Deliverables Roadmap D5 - 1 Copyright JEA ™ 2003 Define Measure Problem?? VOC? VOB ?? CTQs?? Problem??? $$ Why Do This?? COPQ?? Customer Satisfaction??? $$ 1 D Define VOC, VOB and CTQs 2 D Define Project Boundaries 3 D Quantify Project Value 4 D Develop Project Management Plan 5 M Document Process 6 M Prioritize list of X’s S U P P L I E R S C U S T O M E R S Outputs Inputs Process

2. 15 Deliverables Roadmap D5 - 2 Copyright JEA ™ 2003 Analyze Measure 8 M Validate Measurement System 9 M Establish Baseline Process Capability 7 M Create Data Collection Plan Gage R&R Col # 1 2 3 4 5 6 Inspector A B Sample # 1st Trial 2nd Trial Diff 1st Trial 2nd Trial Diff 1 2.0 1.0 1.0 1.5 1.5 0.0 2 2.0 3.0 1.0 2.5 2.5 0.0 3 1.5 1.0 0.5 2.0 1.5 0.5 4 3.0 3.0 0.0 2.0 2.5 0.5 5 2.0 1.5 0.5 1.5 0.5 1.0 Totals 10.5 9.5 3.0 9.5 8.5 2.0 Averages 2.1 1.9 0.6 1.9 1.7 0.4 Sum 4.0 Sum 3.6 X A 2.0 X B 1.8 R A R B Col # 1 2 3 4 5 6 Inspector A B Sample # 1st Trial 2nd Trial Diff 1st Trial 2nd Trial Diff 1 2.0 1.0 1.0 1.5 1.5 0.0 2 2.0 3.0 1.0 2.5 2.5 0.0 3 1.5 1.0 0.5 2.0 1.5 0.5 4 3.0 3.0 0.0 2.0 2.5 0.5 5 2.0 1.5 0.5 1.5 0.5 1.0 Totals 10.5 9.5 3.0 9.5 8.5 2.0 Averages 2.1 1.9 0.6 1.9 1.7 0.4 Sum 4.0 Sum 3.6 X A 2.0 X B 1.8 R A R A R B R B 10 A Determine Critical X’s Improve 12 I Prioritized List of Solutions 13 I Pilot Best Solution Design of Experiments Piloting Test Full scale Original Pilot the solution on a small scale and evaluate the results Change Management and Revalidation Before After Step 4 changes implemented } Improvement Target } Remaining Gap Good } Improvement Before After A1 A2 A3 A4 A2 A1 A3 A4 Before After Step 4 changes implemented } Improvement Target } Remaining Gap Good } Improvement Before After A1 A2 A3 A4 A2 A1 A3 A4 Before After Step 4 changes implemented } Improvement Target } Remaining Gap Good } Improvement Before After A1 A2 A3 A4 A2 A1 A3 A4 Qualification, Validation, Control 14 C Create Control System 15 C Finalize Project Documentation Work Instructions Control/Check Points Response to Abnormality Notes Code # Charac - teristics Control Limits Method Who Immediate Fix Permanent Fix Who Flowchart 2 12 Product Name Process Name Process Code # Date of Issue: Issued by: Approved by: Revision Date Reason Signature 1 Work Instructions Work Instructions Control/Check Points Response to Abnormality Notes Code # Charac - teristics Charac - teristics Control Limits Control Limits Method Who Immediate Fix Immediate Fix Permanent Fix Permanent Fix Who Flowchart 2 12 Product Name Process Name Process Code # Date of Issue: Issued by: Approved by: Revision Date Reason Signature 1 SPC/Process Map Improve Operational Definition and Procedures Data Collection Plan What questions do you want to answer? Data What Measure type/ Data type How measured Related conditions Sampling notes How/ where How will you ensure consistency and stability? What is your plan for starting data collection? Operational Definition and Procedures Data Collection Plan What questions do you want to answer? Data What Measure type/ Data type How measured Related conditions Sampling notes How/ where How will you ensure consistency and stability? What is your plan for starting data collection? Ho6w will the data be displayed? *** Completed PowerPoint Presentation UCL X LCL 0 1000 - 1000 10 20 30 Control Chart 11 G Develop the Interactions Matrix Green It Up