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 ..