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DMAIC – a logical flow to problem solving Define Measure Analyse Improve Control the Problem the Process Gain project approval An iterative approach © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Close the project

The flow of the Define Phase Define Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval “To develop a clear project charter based on a real problem that is relevant to the customer, and that will provide significant benefits to the organisation. ” © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Define Phase Define Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval Who? Where? When? How? How does the problem link to the customer? What’s wrong? What do you want to achieve? Are you clear which process the problem relates to? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Does the project have the buy-in to proceed and succeed?

The flow of the Define Phase Define Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval Who? Where? When? How? How does the problem link to the customer? What’s wrong? What do you want to achieve? Are you clear which process the problem relates to? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Does the project have the buy-in to proceed and succeed?

The flow of the Define Phase Define Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval Who? Where? When? How? How does the problem link to the customer? What’s wrong? What do you want to achieve? Are you clear which process the problem relates to? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Does the project have the buy-in to proceed and succeed?

The flow of the Define Phase Define Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval Who? Where? When? How? How does the problem link to the customer? What’s wrong? What do you want to achieve? Are you clear which process the problem relates to? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Does the project have the buy-in to proceed and succeed?

The flow of the Define Phase Define Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval Who? Where? When? How? How does the problem link to the customer? What’s wrong? What do you want to achieve? Are you clear which process the problem relates to? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Does the project have the buy-in to proceed and succeed?

The flow of the Define Phase Define Measure Analyse Improve Control Define the business case Understand the customer Define the process Manage the project Gain project approval Who? Where? When? How? How does the problem link to the customer? What’s wrong? What do you want to achieve? Are you clear which process the problem relates to? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 Does the project have the buy-in to proceed and succeed?

The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential “To understand baseline the current performance of the process, through a set of relevant and robust measures (KPIs). ” © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential How does the process currently behave? When and where does the data come from? How do you measure the problem? Does the data represent what you think it does? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 What is the current performance of the process with respect to the customer?

The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential How does the process currently behave? When and where does the data come from? How do you measure the problem? Does the data represent what you think it does? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 What is the current performance of the process with respect to the customer?

The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential How does the process currently behave? When and where does the data come from? How do you measure the problem? Does the data represent what you think it does? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 What is the current performance of the process with respect to the customer?

The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential How does the process currently behave? When and where does the data come from? How do you measure the problem? Does the data represent what you think it does? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 What is the current performance of the process with respect to the customer?

The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential How does the process currently behave? When and where does the data come from? How do you measure the problem? Does the data represent what you think it does? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 What is the current performance of the process with respect to the customer?

The flow of the Measure Phase Define Measure Analyse Improve Control Develop process measures Collect process data Check the data quality Understand process behaviour Baseline Process capability & potential How does the process currently behave? When and where does the data come from? How do you measure the problem? Does the data represent what you think it does? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 What is the current performance of the process with respect to the customer?

The flow of the Analyse Phase Define Analyse the process Measure Analyse Develop theories and ideas (possible root causes) Improve Analyse the data Control Verify root causes and understand cause and effect “To find the root causes of the problem, and understand/quantify their effect on process performance. ” © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase Define Analyse the process Measure Analyse Develop theories and ideas (possible root causes) Improve Analyse the data Verify root causes and understand cause and effect How does the root cause affect the process output? What does the existing process knowledge say? How does the process actually work? Control What does the data say? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase Define Analyse the process Measure Analyse Develop theories and ideas (possible root causes) Improve Analyse the data Verify root causes and understand cause and effect How does the root cause affect the process output? What does the existing process knowledge say? How does the process actually work? Control What does the data say? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase Define Analyse the process Measure Analyse Develop theories and ideas (possible root causes) Improve Analyse the data Verify root causes and understand cause and effect How does the root cause affect the process output? What does the existing process knowledge say? How does the process actually work? Control What does the data say? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase Define Analyse the process Measure Analyse Develop theories and ideas (possible root causes) Improve Analyse the data Verify root causes and understand cause and effect How does the root cause affect the process output? What does the existing process knowledge say? How does the process actually work? Control What does the data say? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Analyse Phase Define Analyse the process Measure Analyse Develop theories and ideas (possible root causes) Improve Analyse the data Verify root causes and understand cause and effect How does the root cause affect the process output? What does the existing process knowledge say? How does the process actually work? Control What does the data say? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase Define Measure Generate potential solutions Select the best solutions Analyse Improve Assess the risks Control Pilot and implement “To develop, select and implement the best solutions, with controlled risks. ” © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase Define Generate potential solutions Measure Select the best solutions Analyse Improve Assess the risks Pilot and implement When, where and how will the solutions be implemented? Which solutions are most likely to work? What are all the different possible solutions? Control What are the risks of implementing the solutions? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase Define Generate potential solutions Measure Select the best solutions Analyse Improve Assess the risks Pilot and implement When, where and how will the solutions be implemented? Which solutions are most likely to work? What are all the different possible solutions? Control What are the risks of implementing the solutions? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase Define Generate potential solutions Measure Select the best solutions Analyse Improve Assess the risks Pilot and implement When, where and how will the solutions be implemented? Which solutions are most likely to work? What are all the different possible solutions? Control What are the risks of implementing the solutions? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase Define Generate potential solutions Measure Select the best solutions Analyse Improve Assess the risks Pilot and implement When, where and how will the solutions be implemented? Which solutions are most likely to work? What are all the different possible solutions? Control What are the risks of implementing the solutions? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Improve Phase Define Generate potential solutions Measure Select the best solutions Analyse Improve Assess the risks Pilot and implement When, where and how will the solutions be implemented? Which solutions are most likely to work? What are all the different possible solutions? Control What are the risks of implementing the solutions? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase Define Measure Implement ongoing measurement Standardise the solutions Analyse Improve Quantify the improvement Control Close the project “To ensure the solutions are embedded, the process has robust controls, and the project has clear closure. ” © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase Define Implement ongoing measurement Measure Standardise the solutions Analyse Improve Quantify the improvement Close the project Does the project have a clear closure process? Have the changes become ‘business as usual‘? How will the process be measured after the project? Control Has the project goal been achieved? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase Define Implement ongoing measurement Measure Standardise the solutions Analyse Improve Quantify the improvement Close the project Does the project have a clear closure process? Have the changes become ‘business as usual‘? How will the process be measured after the project? Control Has the project goal been achieved? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase Define Implement ongoing measurement Measure Standardise the solutions Analyse Improve Quantify the improvement Close the project Does the project have a clear closure process? Have the changes become ‘business as usual‘? How will the process be measured after the project? Control Has the project goal been achieved? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase Define Implement ongoing measurement Measure Standardise the solutions Analyse Improve Quantify the improvement Close the project Does the project have a clear closure process? Have the changes become ‘business as usual‘? How will the process be measured after the project? Control Has the project goal been achieved? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The flow of the Control Phase Define Implement ongoing measurement Measure Standardise the solutions Analyse Improve Quantify the improvement Close the project Does the project have a clear closure process? Have the changes become ‘business as usual‘? How will the process be measured after the project? Control Has the project goal been achieved? © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Measurement System Analysis Routemap The tools for assessing the measurement system… Rule of tens Start here Is the resolution acceptable? Minitab’s ‘number of distinct categories’ Possible actions for improving the measurement system… No Check for rounding during data collection. Use full resolution of measurement system. Improve resolution of measurement system (upgrade or replace equipment or system). Yes Attribute GR&R – with a known standard MSA Drilldown Is the level of bias (accuracy) acceptable? No Calibrate the measurement system. Improve/communicate the operational definition. Redesign measurement system to reflect the operational definition. No Same as above, plus: Develop operating procedures for use of measurement system, and train users. Ensure measurement system is fit for purpose. Yes Gage R&R Study Attribute GR&R Study MSA Drilldown Is the level of precision acceptable? Yes Move on with the project! © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Process Capability Routemap Calculate the % Defective Clarify if your % defective is short or long term Convert into a Sigma Level Calculate Sigma Shift Continuous Data LSL USL Short Term Count Data %ST ZST Short Term Metrics Good Bad 0 Sigma Shift ZSHIFT 1 2 Defects 3 Attribute Data Long %LT Term PPM DPMO ZLT Long Term Metrics You can use the PPM or DPMO metrics to present the % defective in the long term. Good Bad © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The Process Door Routemap Getting to know the process as it actually happens… - Process Mapping & Value Stream Mapping - Time Value Maps and Value Add Charts - Seven Wastes and Spaghetti Diagrams Understand which process inputs are critical to customer requirements… - Cause and Effect Matrix Assessing what could go wrong and where… - Failure Mode and Effects Analysis (FMEA) Understanding what does go wrong in the process and where… - Affinity Diagrams - Measles Charts Identifying possible root causes… - Brainstorming Investigate a defect to understand its root cause… - 5 Whys Structure possible root causes in a logical manner… - Fishbone (Cause and Effect) Diagrams © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

The Data Door Routemap For graphical analysis… For statistical analysis… Deciding if data fits a particular model… Looking at distributions… - Histogram, Dot Plot - Minitab’s Graphical Summary - Probability Plot - Normality Test (Anderson Darling) - Individual Distribution Identification Deciding if changes over time are significant… Looking for changes over time… - Time Series Plot, Trend Analysis Comparing distributions or groups of data… - Box Plots and Individual Value Plots - Multi-Vari Chart Comparing proportions and percentages… Deciding if groups of data are different, and quantifying the difference… - Confidence Intervals - Hypothesis testing Quantifying the relationships between process inputs and outputs… - 100% Stacked Bar Chart Looking for relationships between data sets… - Scatter Plot, Matrix Plot - Bubble Plot Looking at different categories of data… - Pareto Chart - Statistical Process Control (SPC) - Run Charts - Correlation & Regression - Simple Regression, Fitted Line Plot, - Multiple Regression, Binary Logistic Regression Adjusting the process to look for relationships between its inputs and outputs… - Design of Experiments (DOE) © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Hypothesis Tests for Averages Start here: You want to compare the averages of some samples of data to decide if they are statistically different. Not sure Tukey’s Quick Test For comparing the averages of two samples. One 1 Sample t-Test For comparing the average of one sample against a specific target or historical average. Are the samples Normally distributed ? No Yes How many samples do you want to compare ? Two 2 Sample t-Test For comparing the averages of two samples against each other. or Paired t-Test For comparing the averages of two samples that are linked in pairs. © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906 You could try transforming the data using Data Transformation. OR You could compare the median values of the samples instead. Three or more One Way ANOVA For comparing the averages of three or more samples against each other.

Hypothesis Tests for Medians Start here: You want to compare the medians of some samples of data to decide if they are ‘statistically’ different. Yes Don’t forget that you can also test for differences in average. Are the samples Normally distributed? No How many samples do you want to compare? Two or more One Are there any obvious outliers in your samples? Yes No 1 Sample Sign Test Mood’s Median Test Kruskal-Wallis Test For comparing the median of one sample against a specific target or historical average. For comparing the medians of two or more samples (that have outliers) against each other. For comparing the medians of two or more samples (with no outliers) against each other. © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Hypothesis Tests for Standard Deviation You want to compare the standard deviation of some samples of data to decide if their variation is statistically different. Start here: Are the samples Normally distributed? No Yes How many samples do you want to compare? Two Three or more Levene’s Test F-Test Bartlett’s Test For comparing the standard deviations of two or more samples that are not Normally distributed. For comparing the standard deviations of two samples that are Normally distributed. For comparing the standard deviations of three or more samples that are Normally distributed. © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Hypothesis Tests for Proportions You want to compare the proportions or percentages of different samples of data to decide if they are statistically different. Start here: How many proportions do you want to compare ? One Three or more Two 1 Proportion Test 2 Proportions Test Chi-Square Test For comparing a proportion against a specific target or historical proportion. For comparing two proportions against each other. For comparing three or more proportions against each other. © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906

Statistical Process Control - Routemap Start here: What type of data do you have? Continuous Count Is the data in individuals or in rational subgroups? Attribute U Chart P Chart For analysing the Count or Defects per Unit (DPU) For analysing proportions or percentages. Or Individuals I-MR Chart For analysing individual data points Or Laney U’ Chart Laney P’ Chart For analysing Counts or Defects per Unit with larger samples For analysing proportions or percentages with larger samples. Subgroups X Bar–R Chart For analysing the averages of small subgroups (2 -9). OR X Bar-S Chart For analysing the average of large subgroups (more than 10). © OPEX Resources Ltd. 2004 -2019 From ‘Lean Six Sigma and Minitab’, ISBN 9780995789906