DMAIC Process Flashcards
What are the dimensions of Six Sigma?
Quality
Vision
Philosophy
Methodology
What is the Vision of Six Sigma?
Zero Defects - but we know we can’t have 0 so we striver for 3.4 DPMO
What is the key figure used in Six Sigma?
Standard Deviation as it represents the +-6 standard deviations
What is the Philosophy of Six Sigma?
Put the customer in focus - what are the customer requirements?
What is the main Methodology for Six Sigma?
DMAIC
What does DMAIC stand for?
Define
Measure
Analyze
Improve
Control
What are the % intervals of each standard deviation from the mean?
~68% of the area is within 1 interval
~95% of the area is within 2 intervals
~99.99997% of the area is within 3 intervals (this is also how we get 3.4 DPMO)
What is the main question being answered by the DEFINE phase?
What is the problem?
What is the main question being asked by the MEASURE phase?
How big is the problem?
What is the main question being asked by the ANALYZE phase?
What causes the problem?
What question is answered by the IMPROVE phase?
How to solve the problem?
What question is answered by the CONTROL phase?
How to ensure the optimization?
What does PDCA stand for?
Plan, Do, Check, Adapt
What is the mindset of Six Sigma?
Reduce variation
Focus on the effectiveness = “doing the right things”
What is the mindset of LEAN?
Remove waste
Focus on the efficiency = “doing the things right”
What does JDI stand for?
Just Do It
What model is used for a Cause Analysis project?
DMAIC
What model is used for a Design project?
DMADV
What are the 3 main criteria for a DMAIC project?
Existing process (with a problem)
No solutions
No causes
What are the 5 criteria for a DMAIC project?
Existing process (with a problem)
No solution
No cause
Manageable size (3-6 months for GB)
There should be an essential benefit (qualitative or quantitative)
What does RACI stand for?
Responsible
Accountable
Consulted
Informed
Who is Responsible for the project success?
Project Leader (GB/BB)
Who is Accountable for the project success?
Project Sponsor
What are the sections of the Project Charter?
Initial Situation
Problem
Goal
Team
Timeline
Benefit
What is the purpose of the ‘Initial Situation’ in the Project Charter?
The initial situation is describing the urgency using the ‘whys’ (why should we do it, why should we do it now, and what happens if we don’t).
What is the purpose of the Problem Statement on the Project Charter?
The impacts (symptom to the customer of business). Describe with facts and data WITHOUT writing any possible root causes!
What is the purpose of the Goal Statement on the Project Charter?
We mirror the Problem to the Goal statement using the same metrics and a decrease in the defect rate from X% to Y% WITHOUT writing any possible solutions!
What is the PGB triangle?
Problem, Goal, Benefit - inside which is the Scope
What does SMART stand for?
Specific
Measurable
Actionable/Accepted
Relevant/Realistic
Timebound
What 3 tools are used to Scope the project?
Project Frame
Multigenerational Plan
SIPOC
How does the Project Frame tool work?
In the frame is In Scope
Outside the frame is Out of Scope in the ‘parking lot’
On the frame are topics to be discussed later as we continue through our tools
What is a MGP?
Multigenerational plan where phase 1 is to ‘stop the bleeding’, phase 2 is to increase performance, and phase 3 aims to be world class
What does SIPOC stand for?
Supplier
Input
Process
Output
Customer
Why do you use the SIPOC tool?
To scope the process at a high level view, identifying your start and stop points with 5-7 process steps
What are the 3 ways to address the risks in a Risk Matrix?
Eliminate or reduce/minimize either the occurrence or the impact
Transfer the risk to something else
Acceptance
What does WBS stand for?
Work Breakdown Structure
Deliverables that get broken down into sub deliverables
FMEA
Failure
Mode
Effectiveness
Analysis
Who is the Human Factor referring to in Stakeholder Management?
Everybody who is either directly or indirectly affected by the project or could have an important/critical effect on it
Who do you share the Stakeholder Analysis with?
NO ONE - keep the information confidential
Provide the motivation for each of the TPC concerns & motives in stakeholder management
Technical - “I can’t do it”
Political - “I’m not allowed to do it”
Cultural - “I don’t want to do it”
What does CTC & CTB stand for?
Critical to Customer
Critical to Business
What does VOC & VOB stand for?
Voice of the Customer
Voice of the Business
What must a CTC be in order for it to be usable for our project?
Specific & Measurable as this is what we’ll be measuring in the Measure phase.
It should be an each or every statement and should be worded in the positive sense ‘each ____ SHOULD’ instead of ‘each ____ should NOT’
What is the Tool 1 used for?
Tool 1 takes the VOC (real customer feedback) in one column, identifies what the ‘True Need’ is from that feedback in the second column, and creates a CTC that is specific, measurable, and positive with an each/every statement in the third column
Gate Reviews - What, Why, Who, When, and How Long?
What - it’s a formal event
Why - to update your sponsor and receive acceptance to move to the next phase
Who - project leader, project sponsor, coach (optional)
When - end of each phase
How Long - 30 minutes max
What is another name for the Tool 2?
Output Measurement Matrix
What goes into the rows of the Tool 2?
The 1-3 CTCs identified in Tool 1
What are the Ys in the Tool 2?
Potential measurements that show us the degree of fulfillment of the CTCs
What do we use Tool 2 for?
To identify Ys (potential output measurements) that could be used to measure the CTCs and identify if each CTC/Y combination have a High impact, Medium, Low, and None
What are the 4 steps of Data Collection?
Clarify goals
Develop definitions and procedures
Collect data
Improve consistency
What are the 2 types of data?
Discrete
Continuous
List some examples of Discrete data
Categories
Counts/whole numbers
People
Binary data
List some examples of Continuous data
Time
Length
Weight
Temperature
Something you need to measure
Which type of data do we prefer to use in our projects?
Continuous as it holds more information and it can be transferred into discrete data as necessary
What are the 3 factors that can actively affect the sample size?
Effort - Time, money, resources
Confidence Level - indicated by a ‘z’
Granularity (Precision) - also known as the margin of error. Indicated by delta (triangle)
What are the confidence factors for 95% and 99%?
95% = 1.96 confidence factor
99% = 2.54 confidence factor
What is the symbol used to represent the Sample Size
n
What is the minimum required sample size for Continuous data?
30 samples
What is the minimum required sample size for Discrete data?
100 samples
What do we use to determine the Quality of the Data?
Measurement System Analysis (MSA)
What does the R&R stand for in Gage R&R?
Reproducibility
Repeatability
What is the difference between Repeatability and Reproducibility?
Repeatability is testing if Carolyn can measure something the exact same way every single time
Reproducibility is testing if Liz can measure something the exact same way that Carolyn did every single time
What is the Operational Definition?
The Operational Definition defines ‘What’ is measured ‘How’. It is to be a common understanding while leaving no room for interpretation as all operators must measure the same way. It is created using feedback/discussion with the experts.
If you see both an issue of Repeatability & Reproducibility, which is it categorized as?
Repeatability because if Operator A can’t replicate their own answers, how can you expect Operator B to be able to reproduce what they did
What elements go into calculating the Sample Size for Continuous Data?
n = Sample Size
z = Confidence Level
Delta = Granularity (margin of error)
S = Standard Deviation
What do statistical key figures for Discrete Data show you?
Proportions
What do statistical key figures for Continuous Data show you?
Location and spread
What statistics show the Location of data?
Mean
Median
Quartile
Xmin & Xmax
What statistics show the Spread of data?
Range (Xmax divided by Xmin)
Standard Deviation
What is the final question of the Measure phase?
Is my process capable?
What does Cp stand for?
Capability of process
What does Capability of Process tell us?
Allowed spread vs actual spread
What is the formula for Cp?
(USL-LSL)/6*S
USL = Upper Specification Limit
LSL = Lower Specification Limit
S = Standard Deviation
What does Cpk tell us?
Cpk takes the location into consideration in addition to the allowed spread vs the actual spread
What is the formula for Cpk?
min[(USL-mean)/3S ; (mean-LSL)/3S]
min = take the smallest value of the 2 calculations in the [ ]
USL = Upper Specification Limit
LSL = Lower Specification Limit
S = Standard Deviation
Which Process Capability calculations do we use for Discrete data?
DPU
PPM
DPMO
YIELD
RTY
What does DPU stand for and how do we calculate?
DPU is Defects per Units
DPU = Defects / Total Parts
Ex: You have 3 phones where Phone A has 1 Defect, Phone B has 2 Defects, and Phone C has 3 Defects
This gives us a total of 6 Defects and 3 Total Parts (phones)
DPU = 6 / 3 = 2
What does PPM stand for and how do we calculate it?
PPM is defective Parts Per Million
PPM = (defective parts / total parts) * 1,000,000
Remember - parts per MILLION so you need to multiple by a million
Remember - it’s defective PARTS - not the number of defects ON a part
What does DPMO stand for and how do we calculate it?
DPMO is Defects Per Million Opportunities
DPMO = [defects / (number of parts * opportunities)] * 1,000,000
What is Yield and how do we calculate it?
Yield is the percentage of non-defective parts produced in your process
Yield = (# of good parts / the # of observed parts) * 100
Ex: Our process produced 5 parts, but 4 of them had defects. What is our yield?
Yield = 1/5 * 100% = 20%
What is RTY and how do we calculate it?
RTY stands for Rolled Throughput Yield
If you have the percentage Yield for every process step, how many will come out good at the end? This is your RTY
RTY = Y1 * Y2 * Y3 * Y4…
Note: the yields are all % so you’ll want to convert to a decimal before multiplying (Ex: 89% becomes 0.89)
What does JDI stand for?
Just Do It!
These are your quick wins where there is low cost, consensus among the team, REVERSIBLE, positive impact, and do it either BEFORE or AFTER you capture your data and analyze
What are the necessary criteria to implement a Quick Win?
Low cost/resources
Consensus among the team
REVERSIBLE
Must have a positive impact
Must be done either BEFORE or AFTER you capture your data (Measure) and Analyze
What are 3 statistical figures used to show Discrete data?
Column Chart (Bar Chart)
Pareto
Pie Chart
What are 4 statistical key figures used to show Continuous data?
Histogram
Scatterplot
Box Plot
Bubble Chart
What are the 2 ‘Verifiction Doors’ that you need to choose between when verifying your data in the Analyze phase?
Data
Process
What is the Ishikawa Diagram used for?
It is a holistic approach to brainstorm POSSIBLE root causes (Xs)
What are the 6 Ms of the Ishikawa diagram?
Man
Machine
Method
Measurement System
Material
Mother Nature
What is the 5xWhys and what is its purpose?
When a possible cause is proposed, ask ‘Why’ until you get to the true cause, not something superficial. Ask ‘Why’ up to 5 times (depending on how long you take to get to the true X)
What does C/N/X stand for and what does each mean?
Constant - something fixed that cannot be changed (ex: your facility)
Noise - something that varies over time but isn’t directly addressable (ex: the weather)
X is your Variable and something you CAN control and adjust.
Your X may also have an impact on your N, so you can improve your X to reduce your N
What are the 4 overarching steps in the roadmap of the Analyze phase?
Determine Goals & Scope
Capture Process
Analyze Process
Specify Root Causes
What do you use the Tool 3 for?
Ranking your Tool 2 Ys against your Ishikawa Xs and verifying their potential as root causes
What does Gemba translate to in English?
The place, where the action is
The Gemba only classifies details according to the macro level - True or False?
False
The Gemba CAN classify details according to the macro level, but you can also break it down to the sub processes, micro level, or even go further to includes process steps in the SOP if needed
How many hypothesis can we have for 1 process step/area in the Gemba walk?
As many as you can provide measurement/data sources for
What do we use the Flow Chart for?
To see the sequence of events, the start/stop, and the decision
What do we use the Swim Lane for?
To see handovers/interfaces and the roles & responsibilities
Sometimes called a Process Function Diagram (PFD)
When do we use a Spaghetti Diagram?
Most commonly used in production, but can be used anywhere that you have a layout of the As-Is state of your process. You draw a map of the physical locations/tables and track the movement of materials and/or people
What do we use the Spaghetti Diagram for?
Tracking the movement and the transport of man and material. It’s a very easy to understand tool because it’s visually obvious if there is an issue
What do we use the Value Stream Map (VSM) for?
Looking at the material flow & informational flow (who is talking to who), process lead time, inventory, and relevant process information
What is the purpose of the Value Analysis?
The whole purpose is to find room for improvement
What is the purpose of the Value Analysis?
The whole purpose is to find room for improvement
