Green Belt Workshop

Chapter 12

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 DMAIC Roadmap
Main Main
Step Description Topics
Focus Deliverable
1 Generate Project Ideas -CTQ identification from VOC, VOB, COPQ
Approved
Define

2 Select a Project -DMAIC vs Kaizen, GB vs BB

Y 3 Finalize Project Charter and High-level -Project Charter and its elements, Process Map Project
Process Map Charter
4 Finalize Project Y & Performance Standards -Operational Definition of Y/CTQ
Measure

5 Validate Measurement System for Y
Y 6 Measure Current Performance and Gap
7 List all Potential X’s
Analyze
-Logical Validation, Attribute Agreement Analysis Baseline
-Sigma Level, Performance Indices, DPU, DPMO, Performance
Yield
-5 Why, Fishbone, Affinity Diagram

8 Identify Critical X’s -Scatter Plots, Pareto Plots, FMEA, Hypothesis Validated
X 9 Verify sufficiency of Critical X’s for the Testing (2 proportion, Chi-square, 2 sample T, Root Causes
project ANOVA, Correlation & Regression)
10 Generate and Evaluate Alternative Solutions -Solution generation and evaluation techniques
Improve

11 Select and Optimize best solution -Introduction to DOE Selected

X 12 Pilot, Implement and Validate the solution -Pilot benefits and validation Solution

13 Implement Control System for Critical X’s -Control Plan, Mistake Proofing
Control

14 Validate Controls -Control Charts

X, Y 15 Documentation, Transfer to Process Owner, -Annualized Benefits, Transfer of project Control Plan
Project Closure

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Control Roadmap

• Implement control system for Critical X’s

Step 13

• Validate the controls

Step 14

• Documentation
Step 15 • Transfer and Closure

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 Selecting Control Charts

TYPE OF DATA

Count or Classification Measurement

(Attribute Data) (Variable Data)

Count Classification

Defects Defectives

Fixed Variable Fixed Variable Subgroup Subgroup Subgroup

Sample Size Sample Size Sample Size Sample Size Size of 1 Size < 8 Size > 8

C Chart U Chart NP Chart P Chart I-MR X-bar & R X-bar & S

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Which control chart should we use?
1. You are a working in a paint company. After one color is manufactured as
per demand another color as taken up. There is a change-over process
involved when switching from one color to another. Use an appropriate chart
to monitor the change-over time.
Worksheet: Changeover time
2. A manufacturer of hair products needs to monitor the pH of its shampoo.
The normal pH of hair is slightly acidic, in the range of 4.5-5.5. To maintain hair
strength and vitality, shampoo and conditioning products should be pH
balanced with hair. In order to ensure quality, six samples are collected at
regular time intervals and their pH is recorded. Use an appropriate chart to
monitor the process.
Worksheet: Sunwool
3. You are manager in inbound call centre. You want to monitor the Average
Handling time of Technical Troubleshooting process. You randomly monitor
the Handling time of 12 calls every day. Use an appropriate chart and draw
appropriate conclusions.
Worksheet: AHT

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I-MR Chart: Changeover time
Stat > Control Charts > Variables Charts for Individuals > I-MR

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I-MR Chart: Changeover time

I-MR Chart of Changeover time (min)

UCL=123.23
120
Individual Value

100 _
X=95.88

80

LCL=68.53
1 7 13 19 25 31 37 43 49 55
Observation

UCL=33.60
30
Moving Range

20

__
10 MR=10.28

0 LCL=0
1 7 13 19 25 31 37 43 49 55
Observation

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Xbar-R Chart: Sunwool
Stat > Control Charts > Variables Charts for Subgroups > Xbar-R

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Xbar-R Chart: Sunwool
Xbar-R Chart of pH
5.4 1
1

UCL=5.2598
5.2
Sample Mean

__
5.0 X=4.9918

4.8
1
LCL=4.7238
1
4.6
1 5 9 13 17 21 25 29 33 37
Sample

UCL=1.111
1.00

0.75
Sample Range

_
R=0.555
0.50

0.25

0.00 LCL=0
1 5 9 13 17 21 25 29 33 37
Sample

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Xbar-S Chart: AHT
Stat > Control Charts > Variables Charts for Subgroups > Xbar-S

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Xbar-S Chart: AHT

Xbar-S Chart of Call 1, ..., Call 12

16.8 UCL=16.907

15.6
Sample Mean

14.4 __
X=14.052

13.2

12.0

LCL=11.197
1 4 7 10 13 16 19 22 25 28
Sample

UCL=5.307
5

4
Sample StDev

_
S=3.223
3

1 LCL=1.139
1 4 7 10 13 16 19 22 25 28
Sample

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Control Roadmap

• Implement control system for Critical X’s

Step 13

• Validate the controls

Step 14

• Documentation
Step 15 • Transfer and Closure

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Document Solution and Benefits
✓ Appropriate documentation of solution is important for
review and replication purpose

✓ The results of the improvement and financial benefits need to

be monitored (generally) for one year

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Transfer to Project Owner, Project Closure

✓ Hand over the Control Plan to the Process Owner

✓ Get a formal sign off of the Sponsor on the results of the

project

✓ Identify Best Practices and replication opportunities and

advise the Process owner on the same

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Control Phase Summary
Key points to remember:

1. Control Plan is created to monitor and sustain improved performance. A

control plan may have
a. Audit plans
b. Risk Mitigation Plans
c. Statistical Process/ Quality Control Measures
d. Visual Controls
e. Poka Yoke Measures

2. Control charts detect the presence of special cause and alerts us. Control
charts don’t assess capability or conformance to specification. It only helps
us determine process stability.

3. Control plan is shared with the process owner, discussed and process is
handed over to the process owner. Process owner diligently follows the
control plan to sustain performance
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Outputs of Control Phase
✓ Control Plan

✓ Documentation of Project Findings

✓ Training & Communication Plan

✓ Transfer to Process Owner

✓ Validation of Financial Benefits

The main output of the
Control phase is the
Control Plan

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Control Tollgate Checklist Part 1
✓ Has the team prepared all the essential documentation for the improved
process, including revised SOP, a training plan, and a process control system?
✓ Has the necessary training for process owners/operators been performed?
✓ Have the right measures been selected, and documented as part of the
Process Control System? Who owns the measures? What happens if
minimum performance is not achieved?
✓ Has the solution been effectively implemented? Has the team compiled
results data confirming that the solution has achieved the goals defined in
the Project Charter?
✓ Has the Financial Benefit Summary been completed?
✓ Has the process been transitioned to the Process Owner, to take over
responsibility for managing continuing operations?
✓ Has a final Storyboard documenting the project work been developed?
✓ Has the team forwarded other issues/opportunities, which were not able to
be addressed, to senior management?
✓ Have “lessons learned” been captured?
✓ Have replication opportunities been identified and communicated?
✓ Has the hard work and successful efforts of our team been celebrated?
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Control Tollgate Review Checklist Part 2
Project Charter – Confirm that the project will make a significant impact on the
Business
➢ How have you confirmed that new process meets the expectations set out
in the Goal Statement?
➢ What are the revised Business Benefits expected to be?
➢ What Business Benefits have reached the bottom line?
➢ Does Business strategy still drive the project?
Measurement System Analysis – How will you ensure that the Measurement
process remains good enough to retain the project benefit and meet customer
needs?
➢ What is your Control Plan to ensure that Measurement processes for KPOVs
and KPIVs will remain good enough to retain the process improvement and
meet customer needs?
➢ Have you implemented the Measurement Control Plan?
Capability Analysis – What is the new capability of key Output Variables and
root causes?
➢ What is the final capability of the KPOVs?
➢ How reliable are your capability estimates? (Is the process stable?)
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Control Tollgate Review Checklist Part 3
Control Plan – How will you ensure that the Process benefit will be retained?
➢ Have you completed your final FMEA with revised ratings?
➢ Is there a control plan in place for each KPIV?
➢ How does this control plan ensure that the process will perform at the
improved level?
➢ What key procedures are required to maintain control?
➢ What are the corrective action procedures (Reaction Plan)?
➢ Have you updated SOPs, if applicable? Who owns it?
➢ Has the process owner been properly trained to support long term
performance?
➢ How was the process knowledge transferred to support personnel?
➢ Has personnel training been performed and documented? How will new
personnel be trained in process operation and reliability?
➢ Is there a method in place to ensure proper training?
➢ What precisely are the Input Variables specifications?
➢ Who is responsible for control for each KPIV and why is control needed?
➢ What type of control chart is used for monitoring? Who interprets the
chart(s) and takes action?
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Control Tollgate Review Checklist Part 4
➢ What visual controls are included in the control plan (5S, SOP, safety,
special instruction)?
➢ Are the area personnel involved with placement and implementation of
the visual controls?
➢ What error-prevention methods for KPIVs are included in the control plan?
➢ Were the area personnel involved with the error-prevention solutions and
implementation?
➢ Does the data support that the solutions implemented are working?
Project Management – Does the Process Owner accept the revised process
and commit to maintain the improved performance?
➢ Has the Process been turned over to the local Process Owner?
➢ What is the plan to detect degradation in the performance of the
implemented improvement(s) and correct the condition?
➢ What issues/concerns do you have on long-term maintenance of the
improved performance resulting from your project's implementation?
➢ Have you updated your Storyboard?
➢ What is the agreed upon date for the Sustain-Certify Gate (or Control Gate
if Project does not pass the Gate review)?
© Benchmark Six Sigma. All Rights Reserved Page - 20
 DMAIC Roadmap
Main Main
Step Description Topics
Focus Deliverable
1 Generate Project Ideas -CTQ identification from VOC, VOB, COPQ
Approved
Define

2 Select a Project -DMAIC vs Kaizen, GB vs BB

Y 3 Finalize Project Charter and High-level -Project Charter and its elements, Process Map Project
Process Map Charter
4 Finalize Project Y & Performance Standards -Operational Definition of Y/CTQ
Measure

5 Validate Measurement System for Y
Y 6 Measure Current Performance and Gap
7 List all Potential X’s
Analyze
-Logical Validation, Attribute Agreement Analysis Baseline
-Sigma Level, Performance Indices, DPU, DPMO, Performance
Yield
-5 Why, Fishbone, Affinity Diagram

8 Identify Critical X’s -Scatter Plots, Pareto Plots, FMEA, Hypothesis Validated
X 9 Verify sufficiency of Critical X’s for the Testing (2 proportion, Chi-square, 2 sample T, Root Causes
project ANOVA, Correlation & Regression)
10 Generate and Evaluate Alternative Solutions -Solution generation and evaluation techniques
Improve

11 Select and Optimize best solution -Introduction to DOE Selected

X 12 Pilot, Implement and Validate the solution -Pilot benefits and validation Solution

13 Implement Control System for Critical X’s -Control Plan, Mistake Proofing
Control

14 Validate Controls -Control Charts

X, Y 15 Documentation, Transfer to Process Owner, -Annualized Benefits, Transfer of project Control Plan
Project Closure

© Benchmark Six Sigma. All Rights Reserved Page - 21

© Benchmark Six Sigma. All Rights Reserved Page - 22