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Reduce Variability - DMAIC
Textron Six Sigma Elements
Define Phase |
Measure Phase | Analyze Phase |
Improve Phase | Control Phase
Six Sigma is a business philosophy that employs a client-centric,
fact-based approach to reducing variation in order to dramatically improve
quality by eliminating defects and, as a result, reducing cost.
DEFINE PHASE
 | Identify the problem |
| Define client requirements |
For the define stage of your project:
| Who are your key customers and their critical requirements (CTS's)?
|
| What are your key process metrics (KPOV's or Y's) and key deliverables
objectives and milestones? |
| Have you created a high-level process map? |
| Has team been initiated (kick-off)? |
| Have you identified areas where you need to collect data? |
| What is your plan for getting started with your project? |
| What steps will you take first? Have you selected the key players
associated with the project? |
| Has Finance been involved (approved) in the project? |
| What is the objective of the project . . . Vision of the area
management team? |
| Review with process owner, IT and Finance? |
| Project definition refined? |
| Project entered in Tracking System? |
Six Sigma Key Concepts
Average vs. Variation
| Average tells little about client experience. The average is hidden
within the variation of the data. Within the variation of a process are
the defects, which prevent you from consistently achieving your
Entitlement. |
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MEASURE PHASE
| Quantify process performance |
| Calculate Sigma level |
| Measure key steps / inputs |
For the measure stage of your project:
| Have you determined what type of data (KPOV's) is available and how
has it been collected? |
| Baseline control charts over time of the KPOV's? |
| Have you completed a process map (flowchart) and who was involved in
its development? |
| Have you determined the categories of defects as shown in your Pareto
analysis? |
| Have you determined if a technology problem is indicated? If yes, what
do you think it will take to improve it? Are there any other alternatives?
|
| What did you learn when you verified the measurement system on this
project? How did you employ measurement system analysis to your project
and what were your takeaways? |
| Did you identify your next steps? |
| Are you satisfied with the level of cooperation and support that you
are getting? |
| Have you determined the Entitlement of the Process? What process did
you use to determine the Entitlement? |
| Have you finalized performance objectives and project scope? |
| Update project in Tracking System? |
Six Sigma Key Concepts
Entitlement
| Demonstrated examples of superior performance represent your
Entitlement. |
| Entitlement is a statistical term that refers to the short-term
capability of a process . . . That is referred to the best you have been
in the process |
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ANALYZE PHASE
| Identify, verify and quantify root causes |
| Establish improvement targets |
| Validate hypothesis |
For the analyze stage of your project:
| What tools have you used in this phase and how were they helpful? |
| What interim actions have you taken to contain defects until a final
solution can be developed and implemented? Has an FMEA (Failure Modes and
Effects Analysis) been completed? |
| What are your improvement plans and next steps to get there (including
timing, responsibility and expected results)? |
| Are you satisfied with the level of cooperation and support that you
are getting? |
| What other support actions or activities do you need to accelerate
your progress? |
| Is your project statistically a "Mean"issue, a "Variation" issue or
both? |
| Update project in Tracking System? |
Six Sigma Key Concepts
Defects
| Various statistical models uncover the critical factors, which prevent
the majority from performing at the Entitlement. |
| Process change removes the defects and allows performance to shift to
the Entitlement. |
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IMPROVE PHASE
| Create the solution design |
| Validate and pilot the solution |
| Implement improvement plan |
| Test solutions |
For the improve stage of your project:
| What new tools have you used in this phase and how were they helpful?
|
| What are the possible root causes of defects? |
| What product or process design changes are required to achieve your
improvement goals? |
| What are your next steps toward achieving your improvement targets?
|
| Has Finance been involved in the project to fully understand the cost
implications of your improvement plans? |
| Are you satisfied with the level of cooperation and support that you
are getting? |
| What other support actions or activities do you need to accelerate
your progress? |
Six Sigma Key Concepts
Rolled Throughput Yield
Typically, we measure the equality of a given process by calculating the
number of transactions that "pass" the final step in the process. However,
Rolled Throughput Yield accurately measures the cumulative defect rate
across all critical steps in a process.
Y=f(X1 ,X2 ,X3 ,X4 ,X5)
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CONTROL PHASE
| Document procedures |
| Standardize Process |
For the control stage of your project:
| What process controls are being implemented to ensure we "sustain the
gains"? |
| Who is the process owner? Is he or she present? Are they fully aware
that they are responsible for maintaining the process after your team has
completed its project? |
| Is there a plan to revisit this process in the future to ensure the
new capability level is maintained? |
| What is the expected improvement in terms of cost reduction? Has
finance been involved in the project? |
| What new tools have you learned that were used in the phase of the
project? |
| Are you satisfied with the level of cooperation and support that you
received during the project? What should we do differently to better
support the next project? |
Six Sigma Key Concepts
Putting it in Perspective
*Defects Per Million Opportunities
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