Lean Six Sigma: Yellow Belt Advanced

DMAIC Process Storyboard

TEAM FORMATION DEFINE MEASURE
Objective: Select problem/ opportunity Objective: Define the Problem/Opportunity, Customers, Objective: Identify and implement the measures required to establish
theme, select team members Customer Requirements, and Process. baseline performance and quantify the opportunity.
Team charter Key Steps:- Cause and Effect Diagram
Key Steps:- Flowchart •Determine what to measure
•Develop business case •Understand the measures Run chart or
•Develop project team charter •Understand Variation control chart
•Understand Customer Requirements •Assess measurement system
•Understand the Process. •Assess process performance
Output: Problem/Opportunity selected, Output: Team Project Charter, Work Plan, Measurable Output: A quantified picture of the current process
Team members selected. Customer Requirements, Process Map/Process Analysis performance, problem impact. The process sigma rating.
ANALYSE IMPROVE - I : Generate Potential Solutions
Objective: Identify and verify the root cause(s) of the problem. Objective: Determine possible solutions that will address the identified root cause(s) of
Cause and Effect Diagram the problem.
Key Steps:- (Fishbone) Key Steps:-
•Analyse data Checksheet Potential Solutions Action Plan
•Generate potential solutions
•Analyse process
•Determine potential root causes •Assess potential solutions Step 1
Step 2
Step 3

•Hypothesis Testing •Select preferred solution Step 4

Step 5
Pareto Chart Step 6

•Verify root causes •Test/Pilot preferred solution

•Develop implementation plan
Output: Root cause(s) identified. Output: Preferred solution or countermeasures

IMPROVE - II: Implement and Check CONTROL - Standardise FUTURE PLANS

Objective: Implement the preferred solution. Confirm that the Objective: Prevent the problem and its root Objectives: Review team effectiveness, plan to
problem and its root cause(s) have been reduced or eliminated. cause from recurring. address remaining issues and institutionalise the
Key steps:- Key steps:- Flowchart Standard learning.
Before
•Implement preferred solution •Standardise the solution procedure Key Steps:- C D
(standards & procedures) •Review remaining project
After •Verify effectiveness 6
•Document project opportunities I M
•Apply comparative methods •Review other applications
•Implement scorecard A
if necessary. •Review learnings
•Implement controls
Output: Recommendations for future projects and
Output: Confirmation that the best solution to eliminate the Output: Solution embedded and “routinised” in improvements to team processes. Project
problem & its root cause(s) has been implemented. relevant process, procedures and standards. documentation and learnings “pack”

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

DMAIC Process Storyboard

TEAM FORMATION DEFINE MEASURE

ANALYSE IMPROVE - I : Generate Potential Solutions

IMPROVE - II: Implement and Check CONTROL - Standardise FUTURE PLANS

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced
Lean Six Sigma Project Charter
Project Title
Process Expected Financial Impact
Green Belt Telephone Number
Champion Organization/Function
Start Date Target Completion Date

Problem/Opportunity What is the Problem to be solved or the

Definition opportunity this project will exploit.

Objective Improvement target, impact on Sigma,

COQ/COPQ and Customer Satisfaction
Business Case What improvement in business
performance is expected. $ impact and by
when.
Team Members Who are the team members and key experts
to be consulted.
Project Scope Which part of the process will be
investigated
Customer Benefit Who are the final customers. What
benefits will they see and what are their
most critical requirements.
What are key milestone dates for Define completion
Schedule
completion of each stage. Measure completion
Analyse completion
Improve completion
Control completion
Project Completion
© Max Zornada (2011)
 Lean Six Sigma: Yellow Belt Advanced

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

Example: SEFP’s Customer Requirements Statement

Customer: Outputs:

Customer Requirements Measure Target Importance to Customer Priority

Customer Satisfaction Rating
(Importance x
Satisfaction)

What is this customer’s major complaint? What issue would they want us to work on?

Ranking Scheme
Importance to customer: 1 = Nice to Have, 2 = Important, 3 = Critical, Must Have
Customer Satisfaction: 1 = Very Satisfied, 2 = OK. Could be better, 3 = Unhappy, Must be improved

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

Pareto Analysis

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

Fishbone Diagram
People Procedures

Equipment/Systems Materials/Environment
© Max Zornada (2011)
 Lean Six Sigma: Yellow Belt Advanced

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

Potential Solutions Matrix

Cost Ease of % of problem Overall
Potential Solutions
Ranking Implementation it fixes Ranking

Scale: 0 = None, 1 = Low, 3 = Moderate, 9 = Strong

© Max Zornada (2011)

 Lean Six Sigma: Yellow Belt Advanced

© Max Zornada (2011)