DMA I C

Improve Overview

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 DMA I C

Improve Phase
What is it?
The Improve phase confirms that the proposed
solution(s) will meet or exceed the improvement
goals of the project. This phase also identifies the
resources required for a successful full-scale
implementation of the solution.
Why do we do it?
In Improve the solution is tested on a small scale in
a real business environment. This “piloting”
ensures that the causes of variation have been
fixed and that the solution will work when fully
implemented.
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 DMA I C

Improve Phase
What are the key elements?

There are 2 key elements, or deliverables, in

the IMPROVE phase:

1. Identify potential solutions,

2. Pilot the solution in a real environment

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 DMA I C
Improve - Identify
Improvement Strategy
IF…
We need to know how the Xs interact with each
other and the Project Y so that we can predict
process behavior;

THEN…
The Improvement Strategy will most likely involve
Design of Experiments (DOE) and Regression
Analyses.

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 DMA I C

Improve - Identify
Improvement Strategy
IF…
The Xs in the project relate to process flow
problems like rework or the lack of standard
procedures or communication;

THEN…
The Improvement Strategy will most likely use
tools such as Lean Techniques, Mistake Proofing,
Benchmarking, Should Be Maps, Robust Designs
and Best Practices.
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 DMA I C
Improve - Developing
Potential Solutions
Plan & Conduct
Experiments

EN
TH

Develop Transfer Function

Identify Vital & Optimum Settings
Interactions

THEN

Y = 157.3 + 28.5 X1 -102.2 X2 + 53.1 X1 X2

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 DMA I C

Improve - Developing
Potential Solutions
Process Improvement
Principles
Value
“Adding”
Principles
Benefit

Cost
Improvement “Reducing”
Principles Principles Time
Errors

Lean Techniques
Defects
“Contrasting”
Principles

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 DMA I C

Clues to Non-Value Added Work

Reevaluate
Remake Recall
Redo
Recheck
Redesign
Rework Repeat
Revise
Reject Retest Reship
Return
Reissue
Retype
Remeasure

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 DMA I C

Improve - Select the Best Solutions

Pay Off Matrix
Pay Off matrix
o Reduce O2 set point o Optimise 287 Hex system
o Run Boiler 2 fixed & Boiler 1 on float o Stop supply HP to LP
B o Change dP of Header & Relief SP o Service and tune FCV103
E HIGH o Concentrator Ramp down
o Service LCV136
o Change PCV022
N o Precip. Ramp down rate
o VSD for FD fan
E
F
I o Increase range of air flowmeter o Change ‘cam’ to control valve
T o Boiler 1 relief valve setting
LOW

LOW HIGH
EFFORT
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 DMA I C

Improve - Select the Best Solutions

Must Want Matrix
Have on-line Provide Training to
Modify Existing VRU Hire Additional Staff database of previous handle issues faster
cases

“Wants” Criteria Weight Score Weighted Score Weighted Score Weighted Score Weighted
Score Score Score Score

Reduced average speed of

answer 10 9 90 9 90 8 80 9 90

Lower cost of operators 6 5 30 2 12 6 36 6 36

Quickly implementable 8 4 32 10 80 5 40 6 48

Minimal cost to implement 7 3 21 2 14 8 56 6 42

Short payback period 5 3 15 4 20 8 40 8 40

Minimal risks of impact to

customer 10 5 50 10 100 10 100 8 80

Minimal risks of impact to

operations 9 4 36 7 63 9 81 8 72

Acceptable to employees 8 5 40 10 80 10 80 9 72

Total 314 Total 459 Total 513 Total 480

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 DMA I C
Risk Prioritization
• Prioritize Risk Issues using the Risk Matrix:
• Probability/Likelihood of Occurrence
• Impact On Project
Fix before Significant Show
High (9)
Probability of Failure

Change Risk Stopper

(9) (27) (81)

Proceed With Fix before Significant

Med (3)

Caution Change Risk

(3) (9) (27)

Proceed Proceed Fix Before

Low (1)

with Caution With Caution Change

(1) (3) (9)
Low (1) Med (3) High (9)
Impact of Failure 11
 DMA I C

Improve - Piloting the Solution

1. Plan and Prepare the Pilot;

2. Execute Pilot;
3. Analyze Pilot results;
4. Document and Transition

FULL SCALE IMPLEMENTATION

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 DMA I C
1st Screening DOE

StdOrder RunOrder CenterPt Blocks A/O ratio A/A ratio Mill residue

2 1 1 1 1.650 0.22 4
4 2 1 1 1.650 0.28 4
6 3 1 1 1.650 0.22 7
8 4 1 1 1.650 0.28 7
3 5 1 1 1.600 0.28 4
7 6 1 1 1.600 0.28 7
9 7 0 1 1.625 0.25 5.5
5 8 1 1 1.600 0.22 7
1 9 1 1 1.600 0.22 4
This DOE shall be plan after optimisation on the new Gyrotor units
regardless the ilmenite blend. Each run of the trial shall takes 2 days,
where data for second day will be used as a results of the trial.
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 DMA I C

Improve Phase Summary

There are 2 key elements, or deliverables,

in the IMPROVE phase:

1. Identify potential solutions,

2. Pilot the solution in a real
environment also known as Design
Of Experiment or DOE

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 DMA I C
Improve Phase
Team Member Duty
Input from Team Member at Improve phase:
1. Generate potential solution
- Team meeting to agree on improvement
strategy
- Identify potential solution
- Select best solution
- Identify potential risk & abatement plan

2. DOE
- If required DOE, help in getting the trial
completed
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