DMA I C

Measure Overview

MEA
C

SUR
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I A

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 DMA I C

Measure Phase
What is it?
The Measure phase defines the defect(s), gathers
baseline information about the product or process,
and establishes improvement goals.

Why do we do it?
The Measure phase allows us to understand the
present condition of the process before attempting
to identify improvements. Because the Measure
phase is based on valid data, it eliminates
guesswork about how well the process is working.
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 DMA I C

Measure Phase
What are the key elements?
There are 9 key elements, or deliverables, in the
Measure phase:
1. Project Y
2. Performance Standards for Project Y
3. Data Collection Plan
4. Validated Measurement System
5. Data for Project Y
6. Performance and Capability for Project Y
7. Improvement Goal for Project Y
8. Updated Financial Benefits
9. Updated Charter 3
 DMA I C

Measure: Project Y
What is the Project Y?
Project Y is the measurement of what we are trying
to improve in the project. It is a customer-focused
output measure that is closely tied to both the
project problem and the improvement goal.

How is it determined?
The Project Y can be found in the SIPOC (Output),
in the Charter (Problem and Goal Statements) and
from the CTQ tree (Customer requirements).
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 DMA I C

Measure: Project Y
Project Y Examples
- lbs steam / lb product
- number errors / invoice
- % invoices paid on time
- % first pass prime
- lbs monomer / lb polymer
- number truck shipments / month
- hours downtime / month
- pounds of waste disposed /
month
- % raw material decrease / month
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 DMA I C

Measure: Project Y
Project Y Selection Examples
CUSTOMER NEEDS MATRIX Output Measures

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ep am rn
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Ranking
us us ste tw bu blo er
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a m m i n
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Customer Needs Bo Te Na Te Nu Te Nu Te De Te Nu Te Sp t ea Sp
Natural gas usage is < 23.58 GJ/te FPP 10 10 10 10 10 4 7 7 7 7 4 4 7 7 7
Boiler's burner maintenance cost is zero/year 1 1 1 1 1 1 1 4 7 4 1 4 1 1 1
Boiler's tubes repair cost <25K per year 4 1 1 1 1 1 2 7 7 7 7 7 4 1 1
Steam trap maintenance/replacement cost < 8K per year 7 4 7 4 1 10 10 1 1 4 7 4 4 1 1
Safe method to operates boilers 4 4 7 4 1 1 1 7 7 4 1 4 4 1 1
Safe method to operates burners (driers & calciner) 1 4 1 4 7 1 1 4 4 1 1 1 1 7 7
Black smog incident is zero per year 4 4 7 4 1 1 1 7 4 4 1 4 1 1 1
Clear operating instruction for boilers 4 7 7 7 1 4 1 4 4 4 1 4 4 1 1
Clear operating instruction for burners 4 1 1 4 4 1 1 4 4 1 1 1 1 10 10
Achieved production capacity target of 60K per year 10 10 10 10 10 1 4 4 7 7 7 4 7 7 7
HP steam temperature control > 240°C 7 7 10 7 4 10 7 7 7 4 4 7 4 1 1
Demin water final pH control must be at 7.5 to 8.5 7 4 7 4 4 7 7 1 1 10 10 10 10 1 1
Natural gas usage for direr and calciner < 8.9 GJ/te FPP 7 1 1 7 10 1 1 7 4 1 1 1 1 10 10
385 469 439 373 280 311 346 346 358 310 319 331 295 0 295

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 DMA I C
Measure: Performance Standards
for Project Y
What are Performance Standards?
Performance Standards are the boundaries that
define the acceptable values for the
measurement of the process (Project Y). They
are often called specifications or “specs”.

How are Performance Standards determined?

The Performance Standards are set by the
needs of the customer (CTQ). These will
generally include a target value along with upper
and lower specification limits. 7
 DMA I C

Performance Standards for Project Y

Lower Spec Limit

E
BL
E
BL

TA
MORE IS BETTER
A

EP
EPT

C
C

AC
C
A

UN
% FIRST PASS PRIME

Upper Spec Limit

E
BL
LE

TA
B
LESS IS BETTER A

EP
EPT

C
C

AC
C
A

UN
NUMBER ERRORS / INVOICE

Lower Spec Limit Upper Spec Limit

LE

LE
AB LE

AB
B
BULL’S EYE
PT
A

PT
PT
CE

CE
E
AC

AC
C
UN

UN
8
LBS STEAM / LB PRODUCT
 DMA I C

Measure: Data Collection Plan

What is a Data Collection Plan?
A Data Collection Plan is a clear, organized
strategy for identifying and gathering reliable data
about your project.

Why do we do it?
By identifying the correct data, we ensure that we
have a correct representation of the process.
Reliable data always accurately represents the
true nature of the process.
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 DMA I C

Data Collection Plan Overview

• Data collection goals
– What data to measure
– The nature of the data (Inputs, Process, or Outputs)
– What type of data to measure (continuous or discrete)
• Operational definitions and procedures
– Definition of what will be measured
– Definition of how it will be measured
• Other measurements of importance (Xs)
• Defining the sampling plan
– What data to be collected
– Where data to be collected
– When data to be collected
– How much data to be collected
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 DMA I C

Data Collection Plan

Continuous
or
Discrete

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 DMA I C
Measure: Validated Measurement
System
What is Measurement System Analysis?
Measurement System Analysis (MSA) quantifies
the amount of variation in the data that is caused
by the measurement system itself. This helps to
quantify the accuracy of the data being gathered.

Why do we need MSA?

Without a complete understanding of how good
our measurement system is, there is a risk of
calling good data bad (a cost defect) or of calling
bad data good (a quality defect). 12
 DMA I C

The Fundamental Question of MSA Studies

“Is the variation (spread) of my measurement system too large to
study the current level of process variation?”

Total Variability
Product Variability Measurement (observed
(actual variability) Variability variability)

+ =

Must I stop and correct my measurement system

before proceeding on my ‘real’ project? 13
 DMA I C

Measure: Performance & Capability

for Project Y
What does Capability for Project Y mean?

The Capability Analysis for Project Y helps

us establish a baseline measurement of the
current performance of the process.

By looking at the data we collected in this

manner, we can begin to see how “capable”
the process is of meeting the customer’s CTQ
consistently.

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 DMA I C

DATA

Discrete Continuous
Attribute Data
Types

Defects Location
Statistical Spread
Units Measures
Opportunities Shape

Performance
Standards

Six Sigma
Metric: Z
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 DMA I C

Long-Term vs. Short-Term Data

Short-Term
Data

Y
(Continuous)

Long-Term
Data

Time 16
 DMA I C

Visualizing the Components of Variation

Within Group
Variation
Person 1
(Short Term)
Person 2
Person 3
Person 4

Between Group
Total Variation
(Long Term)
X

Total variation is the sum of within and between variation

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 DMA I C

Process Capability Analysis for Data

LSL USL
Process Data
USL 35.0000
Target *
LSL 15.0000
Within
Mean 28.2941
Sample N
StDev (Within) 1.6258
60
Short-term Overall

StDev (Overall) 11.3071 capability

Potential (Within) Capability
Long-term
Z.Bench 4.12 performance
Z.USL 4.12
Z.LSL 8.18
Cpk 1.37

0 10 20 30 40 50 60
Cpm *

Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Z.Bench 0.26 PPM < LSL 166666.67 PPM < LSL 0.00 PPM < LSL 119850.45
Z.USL 0.59 PPM > USL 416666.67 PPM > USL 18.57 PPM > USL 276567.07
Z.LSL 1.18 PPM Total 583333.33 PPM Total 18.57 PPM Total 396417.53
Ppk 0.20
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 DMA I C

Measure: Improvement Goal

What is the Improvement Goal?

The Improvement Goal is a statement in statistical

terms of the improvement desired from the project.

How is this different from the Project Goal?

It’s not different, but only stated differently. In the
Charter, the Project Goal simply said “Improve Y by
10%”. Now we can set a goal in statistical terms
referring to number of defects and sigma value.
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 DMA I C

Measure: Improvement Goal

LSL USL LSL USL

DESIRED
DESIRED
CURRENT
CURRENT

Shift the Mean Do Both (mean and std. dev.)

LSL USL LSL USL

DESIRED

CURRENT
CURRENT

Reduce the Variation Do Nothing !

(standard deviation) 20
 DMA I C

Measure: Updated Charter &

Financial Benefits

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 DMA I C

Measure Phase Summary

There are 9 key elements, or deliverables, in the
Measure phase:
1. Project Y
2. Performance Standards for Project Y
3. Data Collection Plan
4. Validated Measurement System
5. Data for Project Y
6. Performance and Capability for Project Y
7. Improvement Goal for Project Y
8. Updated Financial Benefits
9. Updated Charter
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 DMA I C
Measure Phase
Team Member Duty
Input from Team Member at Measure phase:

1. Project Y selection
- Team brainstorm and select best Project Y
using Matrix
2. Data Collection Plan
- Help collecting data, if in manual
3. MSA
- Gauge Repeatability & Reproducibility
4. Improvement Goal
- Agree with the team Goal 23