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DMAIC is a structured problem-solving methodology used for process improvement. It stands for Define, Measure, Analyze, Improve, and Control. Let’s delve into each stage with few examples:
Define:
In the Define phase, you need to clearly articulate the problem you want to solve or the goal you want to achieve. This step sets the foundation for the entire process.
Example: Suppose you work in a manufacturing company, and the problem you’re addressing is excessive defects in a specific product line. Your goal is to reduce defects to improve product quality.
Project selection may be done based on various themes in a typical organization like as below;
These project themes are then funneled down to the CTQs. These CTQs are the actual project areas which need to be improved. Please refer the below example;
Measure:
In this phase, you quantify and measure the current state of the process, this is also termed as baseline performance of the process chosen for improvement. Identify the critical variables that impact the problem.
Example: You collect data on the number of defects per batch produced. You also measure other relevant factors like machine uptime, operator skill level, machine setting parameters and raw material quality.
Analyze:
In this phase, you analyze the data to understand the root causes of the problem. Use tools like histograms, scatter plots, Pareto charts and hypothesis testing.
Example: After analyzing the data, you discover that defects are highest when a specific machine is used during specific time of the day. The machine maintenance schedule is irregular or incorrect settings, leading to inconsistent performance.
Improve:
In the Improve phase, you develop and implement solutions based on your analysis. Consider various options and select the most effective ones.
Example: To address the machine issue, you decide to:
Regularly maintain the machine: Implement a preventive maintenance schedule.
Machine setting with correct parameters: Implement error proofing in the machine setting activity.
Train operators: Provide training on proper machine operation.
Monitor raw material quality: Work closely with suppliers to ensure consistent materials.
Control:
Finally, in the Control phase, you establish controls to sustain the improvements. These controls prevent reversal of improvements implemented and ensure long-term success.
Example: You set up a monitoring system to track defect rates, machine uptime, setting parameters and operator adherence to procedures. Regular audits ensure that the improvements are maintained.
Please remember that DMAIC is iterative. As you implement changes, continuously monitor and refine the process. Each phase informs the next, leading to sustained improvement over time.
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