1-06 Dmaic Intro

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Confidential - Rockwell Automation 1

ProblemSolving Methodology

DMAIC



2Learning Objectives

• Understand why using a methodology isimportant to problem solving

• Understand the definition of the term DMAIC

• Be able to apply the DMAIC principles to your

project



3The Problem Solving Goal...

Sweet Fruit

Use of a Detailed Methodology

Ground Fruit

Intuition and Logic

Low Hanging Fruit Basic Tools of Problem Solving

B ulk of Fruit Process Characterization &

Optimization



4Goal Alignment Means Knowing & Doing

+ Right People

Right Projects

Right Tools

++ Right Support

Right Results=



5Working The Right Projects

Assess &Select

Deploy &Dig

Set

Performance

Measures

The Right Projects Means…

• Customer & Business Alignment

• Goals Established• SMART

+ Right People

Right Tools+

+ Right Support

Right Results=

Right Projects



6Aligning The Right People

Align

ResourcesDeploy &

Develop

Prioritize &

Train

The Right People Means…

• Knowledge appropriate to task

• Required level of skills

• Positioned & able to impact

Right Tools

++ Right Support

Right Projects

Right Results=

Right People+



7Applying The Right Tools

DMAIC VariationReduction

WasteElimination

The Right Tools Means…

• Proper tool applied to the

problem

• Minimized non-value added

• Reduced process variability

+

+ Right Support

Right People

Right Projects

Right Results

+

Right Tools

=



8Providing The Right Support

ProjectReviews

KnowledgeManagement

Reward &Recognition

The Right Support Means…

• Projects completed on time

• Appropriate behavior rewarded• Best practices shared

Right Tools

+

+ Right People

Right Projects

Right Results=

Right Support+



9Why Use an Improvement Method?

DMAIC

– Provides a framework – Provides common language

– Provides a checklist to prevent

skipping critical steps – Allows you to improve how you

improve



10Overview of DMAIC

1

2

3

4

5DEFINE

MEASURE

ANALYZE

IMPROVE

CONTROL



11DEFINE: Define the Project

• Goal – Define the project’spurpose and scope andget background on

the process and customer• Output

– A clear statement of theintended improvement andhow it is to be measured

– A high level map of the process

– A translation of the “Voice of the

Customer” into “Key QualityCharacteristics”

1

2

3

4

5

DEFINE

MEASURE

ANALYZE

IMPROVE

CONTROL



12DEFINE, (continued)

• Thought Process

DevelopProject

Charter

CreateProcess

Map

CalculatePreliminary

FinancialMeasurement



13MEASURE (the current state)

1

2

3

4

5

DEFINE

MEASURE

ANALYZE

IMPROVE

CONTROL

• Goal – Focus the improvement

effort by gathering

information on

the current situation• Output

– Focus

– Data that pinpoints problem location

or occurrence

– Baseline data on how well the

process meets customer needs

– Understanding of how currentprocess operates

– A more focused problem statement



14MEASURE, (continued)

• Thought Process

Create detailed

process maps

Collect baselinedata on defects

and possiblecausal factors

Plot defectdata

over time and

analyze forspecialcauses

Create & stratifyfrequency plotsand do Pareto

analysis(if appropriate)

ANALYZE Id if C



15ANALYZE: to Identify Causes

1

2

3

4

5

DEFINE

MEASURE

ANALYZE

IMPROVE

CONTROL

• Goal

– Identify root causesand confirm themwith data

• Output

– A theory that hasbeen tested andconfirmed



16ANALYZE, (continued)

• Thought Process

Develop afocusedproblem

statement

Brainstormpotential

causes

Organizepotential

causes

Collect data

Statisticalmethods to

quantify

cause-effectrelationship

IMPROVE



17IMPROVE: Implement Solutions & Evaluate Results

• Goal – Develop, pilot, and implement solutions

that address root causes

– Use data to evaluate both the solutionsand the plans used to carry them out

• Output

– Planned, tested actions that eliminateor reduce the impact of the identifiedroot causes

– Before and After data analysis thatshows how much of the initial gap wasclosed

– A comparison of the plan to actualimplementation

1

2

3

4

5

DEFINE

MEASURE

ANALYZE

IMPROVE

CONTROL

IMPROVE



18IMPROVE, (continued)

• Thought Process

Brainstorm

manypossible

solutions toidentified

root causes

Selectsolution(s)

Developplan(s)

Pilot plan(s)

Implementplan(s)

Quantifyresults

Evaluate thebenefits of

theimprovement

CONTROL



19CONTROL

• Learning Objectives

– Maintain the gains by standardizing

work methods or processes

– Anticipate future improvementsand preserve the lessons from

this effort

– Recognize need for a control plan

• Output

– Documentation of the new method

– Training in the new method

– A system for monitoring itsconsistent use and for checking the results

– Completed documentation and communication

of results, learning, and recommendations

1

2

3

4

5

DEFINE

MEASURE

ANALYZE

IMPROVE

CONTROL

CONTROL



20CONTROL, (continued)

• Thought Process

Makerecommen-dations for

future plans

Develop anddocumentstandardpractices

TrainOngoing

monitoring

Buildprocess for

updatingprocedures

Summarizeand

communicate learnings

Th DMAIC C l



21The DMAIC Cycle

Define • Why must this project be done NOW?• What is the business case for this project?• Who is the customer?• What is the current state?• What will be the future state?• What is the scope of this project?

• What are the intangible deliverables?• What is the due date?

Measure

• What are the key metrics for thisbusiness process?• Are the metrics valid and reliable?• Do we have adequate data on

this process?• How will I measure progress?• How will I measure ultimate

success?

Analyze • Current state analysis• Is the current state as good as the

process can do (entitlement)?• Who will help make the changes?• What resources will we need?• What could cause this change effort

to fail?• What major obstacles do I face in

completing this project?

Improve • What is the work breakdown structure for

this project?• What specific activities are necessary to

meet the project’s goals?• How will I re-integrate the various sub-

projects?• Do the changes produce the desired

effects?

• Any unanticipated consequences?

Control • During the project, how will I control

risk, quality, cost, schedule, scope,and changes to the plan?

• What types of progress reportsshould I send to sponsors?

• How do I assure that the businessgoals of the project wereaccomplished?

• How will I maintain the gainsmade?

1-06 Dmaic Intro

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