Problem Solving Methods - DMAIC

Question 1

What is DMAIC?

Answer 1

a problem solving methodology that stands for Define, Measure, Analyze, Improve and Control

Question 2

What are some example outcomes of a DMAIC project?

Answer 2

• eliminated need for extra staffing
• prevent waste of expensive materials
• reduce harmful by-products
• improve customer satisfaction
• eliminate errors that negatively affect customers
• reduce calls to call centers

Question 3

What is the purpose of the define phase?

Answer 3

to clarify the problem

Question 4

What content is in the project charter?

Answer 4

1) the problem statement
2) primary metric
3) goal for improvement
4) customer expectations

Question 5

Who is typically responsible for the define phase?

Answer 5

the Green Belt and Project Champion

Question 6

Which DMAIC phase is the most important and why?

Answer 6

Define; a poorly defined project will not be successful and will frustrate the team and organization

Question 7

What is the purpose of the measure phase?

Answer 7

to come to a common understanding of the current process

Question 8

Who is involved in the measure phase?

Answer 8

project team, subject matter experts, green belt

Question 9

What is the purpose of the analyze phase?

Answer 9

to determine the root causes of the problem

Question 10

What is a big risk of the analyze phase?

Answer 10

if the work is not done thoroughly, the wrong root cause(s) will be addressed and the problem will remain after the project is completed

Question 11

What is the purpose of the improve phase?

Answer 11

to determine potential solutions

Question 12

What is the purpose of the control phase?

Answer 12

to ensure the sustainability of the improvement

Question 13

What is a big risk of the control phase?

Answer 13

that it is overlooked or not completed which will likely result in the return of the problem

Question 14

What is a control plan?

Answer 14

a plan that documents how the process is to be performed and measured, as well as the steps to take if a problem occurs

Question 15

What is the GB’s role in DMAIC projects?

Answer 15

• subject matter expert in using DMAIC
• facilitation of a team of process subject matter experts
• help the team work through the steps to improve the way they do their work and eliminate problems in the process
• might assist a black belt on a larger project

Question 16

What activities take place in the define phase? (7)

Answer 16

• develop project charter
• develop project plan
• develop stakeholder analysis
• develop communication plans and RACI charts
• identify subject matter experts needed to solve problem
• conduct initial team meeting to develop SIPOC
• gather VOC

Question 17

What activities take place in the measure phase? (5)

Answer 17

• develop a more detailed process map
• evaluate the primary metric measurement system for accuracy and precision
• build a data collection plan
• collect baseline process data
• conduct baseline process capability (compare VOP to VOC)

Question 18

What activities take place in the analyze phase? (6)

Answer 18

• analyze the process map for areas needing improvement
• brainstorm other data that may need to be collected (is an additional tool needed?)
• update the data collection plan
• collect necessary data
• perform data analysis using hypothesis testing
• determine root cause that should be addressed based on process and data analysis

Question 19

What activities take place in the improve phase? (5)

Answer 19

• brainstorm potential solutions
• evaluate and prioritize proposed solutions
• test the most likely solutions with pilots, prototypes, and/or designed experiments
• select the final solutions for implementations
• measure the effects of potential solutions on the primary metric (and additional metrics, if applicable)

Question 20

What activities take place in the control phase? (6)

Answer 20

• train those who perform the process
• perform a measurement system analysis on any new measurement systems
• finish the implementation of solutions
• build control plan
• turn responsibility over to the process owner
• finalize documentation of project and lessons learned

Question 21

What are the define phase deliverables? (7)

Answer 21

1) project charter
2) project plan
3) stakeholder analysis and communication plans
4) RACI charts
5) project team
6) SIPOC
7) customer specification limits

Question 22

What is a SIPOC?

Answer 22

a high level process map that shows suppliers, inputs, process steps, outputs and customers

Question 23

What are the measure phase deliverables? (5)

Answer 23

1) process maps
2) validated or improved measurement systems
3) data collection plan
4) baseline process capability
5) updated project charter and project plan, if needed

Question 24

What are the analyze phase deliverables? (4)

Answer 24

1) updated data collection plan
2) results of process and data analysis
3) verified root causes
4) updated project charter and project plan, if needed

Question 25

What are the improve phase deliverables? (3)

Answer 25

1) pilot results
2) final solutions for implementation
3) updated project charter and project plan, if needed

Question 26

What are the control phase deliverables? (4)

Answer 26

1) updated training plan
2) validated new measurement systems
3) control plan
4) finalized project report