Overview of DMAIC

✓ DMAIC is a structured problem-solving procedure

widely used in quality and process improvement. It
is often associated with six-sigma activities, and
almost all implementations of six sigma use the
DMAIC process for project management and
completion.
Overview of DMAIC
The letters DMAIC form an acronym for the five steps:

✓ Define

✓ Measure

✓ Analyze

✓ Improve

✓ Control
Overview of DMAIC
The letters DMAIC form an acronym for the five steps:

✓ Define

✓ Measure

✓ Analyze

✓ Improve

✓ Control
Overview of DMAIC
Overview of DMAIC
✓ The DMAIC structure encourages creative thinking
about the problem and its solution within the
definition of the original product, process, or
service.
Overview of DMAIC
DEFINE MEASURE ANALYZE IMPROVE CONTROL
Project Charters Process maps Hypothesis Designed SPC and process
and flow charts Tests, experiments control plans
Confidence
Interval
Process maps Cause and Effect Regression
and flow charts Analysis analysis, other
multivariate
methods
Process Failure mode &
Capability effects analysis
Analysis
Gauge R&R Designed
experiments
Control Plans SPC and process
control plans
The Define Step
✓ The objective of the define step of DMAIC is to
identify the project opportunity and to verify or
validate that it represents legitimate breakthrough
potential.
The Define Step
✓ PROJECT CHARTER
This is a short document that contains the following:
➢ a description of the project and its scope
➢ the start and the anticipated completion dates
➢ an initial description of both primary and
secondary metrics that will be used to measure
success and how those metrics align with
business unit and corporate goals
The Define Step
✓ PROJECT CHARTER
This is a short document that contains the following:
➢ the potential benefits to the customer
➢ the potential financial benefits to the organization
➢ milestones that should be accomplished during the
project,
➢ the team members and their roles,and
➢ any additional resources that are likely to be needed
to complete the projectcc
The Define Step
The Define Step
The Define Step
The SIPOC diagram is a high-level map of a process. SIPOC
is an acronym for Suppliers, Input, Process, Output, and
Customers, defined as:
✓ The suppliers are those who provide the information,
material, or other items that are worked on in the process.

✓ The input is the information or material provided.

✓ The process is the set of steps actually required to do the

work.
The Define Step
The SIPOC diagram is a high-level map of a process.
SIPOC is an acronym for Suppliers, Input, Process,
Output, and Customers, defined as:
✓ The output is the product, service, or information sent
to the customer.

✓ The customer is either the external customer or the

next step in the internal business
The Measure Step
The purpose of the measure step is to evaluate
and understand the current state of the process. This
involves collecting data on measures of quality, cost,
and throughput/cycle time. It is important to develop
a list of all of the key process input variables (KPIV)
and the key process output variables (KPOV).
The Measure Step
The purpose of the measure step is to evaluate
and understand the current state of the process. This
involves collecting data on measures of quality, cost,
and throughput/cycle time. It is important to develop
a list of all of the key process input variables (KPIV)
and the key process output variables (KPOV).
The Analyze Step
The objective is to use the data from the
measure step to begin to determine the cause-and-
effect relationships in the process and to understand
the different sources of variability.
The Analyze Step
Useful tools in the Analyze step:

➢ control charts

➢ statistical hypothesis testing and confidence

interval estimation

➢ regression analysis

➢ Failure modes and effects analysis (FMEA)

The Analyze Step
✓ CONTROL CHARTS, which are useful in separating common
cause variability from assignable cause variability.

✓ STATISTICAL HYPOTHESIS TESTING AND CONFIDENCE INTERVAL

ESTIMATION, which can be used to determine if different
conditions of operation produce statistically significantly
different results and to provide information about the
accuracy with which parameters of interest have been
estimated.
The Analyze Step
✓ REGRESSION ANALYSIS, which allows models relating
outcome variables of interest to independent input
variables to be built.

✓ FMEA is used to prioritize the different potential

sources of variability, failures, errors, or defects in a
product or process
The Analyze Step
✓ Failure modes and effects analysis criteria:
➢ The likelihood that something will go wrong (ranked on a 1 to
10 scale with 1 = not likely and 10 = almost certain).
➢ The ability to detect a failure, defect or error (ranked on a 1 to
10 scale with 1 = very likely to detect and 10 = very unlikely to
detect).
➢ The severity of a failure, defect or error (ranked on a 1 to 10
scale with 1 = little impact and 10 = extreme impact, including
extreme financial loss, injury, or loss of life).
The Analyze Step
✓ Failure modes and effects analysis criteria:
➢ The likelihood that something will go wrong (ranked on a 1 to
10 scale with 1 = not likely and 10 = almost certain).
➢ The ability to detect a failure, defect or error (ranked on a 1 to
10 scale with 1 = very likely to detect and 10 = very unlikely to
detect).
➢ The severity of a failure, defect or error (ranked on a 1 to 10
scale with 1 = little impact and 10 = extreme impact, including
extreme financial loss, injury, or loss of life).
The Improve Step
✓ Focus on creative thinking about the specific
changes that can be made in the process and
other things that can be done to have the desired
impact on process performance.
The Improve Step
The objectives of the improve step are to develop a
solution to the problem and to pilot test the solution.

✓ The pilot test is a form of confirmation experiment: it

evaluates and documents the solution and confirms
the solution attains the project goals.
The Control Step
✓ The objectives of the control step are to complete
all remaining work on the project and to hand off
the improved process to the process owner along
with a process control plan and other necessary
procedures to ensure that the gains from the
project will be institutionalized.
The Control Step
✓ The objectives of the control step are to complete
all remaining work on the project and to hand off
the improved process to the process owner along
with a process control plan and other necessary
procedures to ensure that the gains from the
project will be institutionalized.
8D PROBLEM SOLVING METHODOLOGY
HISTORY
✓ It originally created by the U.S. Department of Defense in 1974.

✓ In late 1990s, ford developed a revised version of 8D Problem

Solving Process that they call “GLOBAL 8D” which is the current
global standard for Ford and many other companies in the
automotive supply chain.
8D PROBLEM SOLVING METHODOLOGY
8D PROBLEM SOLVING METHODOLOGY
8D PROBLEM SOLVING METHODOLOGY
TERMINOLOGY

✓ SYMPTOM- A quantifiable event of effect, experienced by a customer that

may indicate the existence of one or more problems.

✓ PROBLEM- A deviation from an existence or standard; a perceived gap

between the existing state and a desired state.

✓ Possible Cause, identified through process variable mapping, brainstorming

or a fishbone diagram, that describes how a problem occur.

✓ Root Cause, A verified that convincingly supports and explains all facts and
thus accounts for the problem.
8D PROBLEM SOLVING METHODOLOGY
BENEFITS
8D PROBLEM SOLVING METHODOLOGY
8D PROCESS