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6Methodology: DMAIC
Robert Setaputra
PDCA / PDSA
PDCA / PDSA is a continuous quality improvement tool.
PDCA is introduced by Shewhart. PDSA is Deming’s version of PDCA.
PDCA
PlanPlan (What) Identify the problem to be examined
Formulate a specific problem statement to clearly define the problem Set measurable and attainable goals Identify stakeholders and develop necessary communication channels to communicate and gain approval
Plan (Why) Divide overall system into individual processes -map the process Brainstorm potential causes for the problem Collect and analyze data to validate the root cause Formulate a hypothesis Verify or revise the original problem statement
Do
Do Establish experimental success criteriaDesign experiment to test hypothesis Gain stakeholder approval and support for the chosen solution Implement the experiment/solution on a trial or pilot basis
Check
Check Gather/analyze data on the solutionValidate hypothesis
Act
Act Identify systemic changes and training needs for full implementation Plan ongoing monitoring of the solutionContinuous improvementLook other improvement opportunities
DMAIC
Define, Measure, Analyze, Improve, Control
Very structured Linked a project directly to financial
benefits.
Check Lists for Potential Project
What is the problem you are trying to address? What are the potential benefits of solving this problem? Will you be able to quantify these benefits in terms of
cost savings, cost avoidance, or improved customer satisfaction if you solve this problem?
Do you have the necessary support and commitment from management/ key stakeholders to solve this problem?
Is the resolution of this problem achievable given your span of influence (i.e., is the scope of the project reasonable)?
Check Lists for Potential Project
What key output variables are needed to measure project success?
Do you have a capable system to measure each of these key output variables?
What key process input variables are you going to examine to determine the root cause(s) of your problem?
Do you have a capable system to measure each of these key input variables?
Do you have the appropriate analytical resources (training, software) necessary to solve this problem?
Potential Project
Waste = Project 10 10 10 10 15 20 = Improvement Easy to understand Short term Big impact
Project Ideas
Sales Reduce the time required to enter orders Improve the process for checking customer credit
Customer Service Reduce number of call transfer
Shipping/Receiving Improve documentation accuracy Improve inspection process Reduce inventory damage and loss
Etc ..
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