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Page 1: DMAIC-Six sigma process Improvement Approach

Boutique product development company It is amazing what you can accomplish when you have a client-centric team to deliver outstanding products.

Page 2: DMAIC-Six sigma process Improvement Approach

Boutique product development company It is amazing what you can accomplish when you have a client-centric team to deliver outstanding products.

Six Sigma DMAIC Maryam Rehmat | Process Engineer.

Arooj Un Nisa | Process Engineer.

Page 3: DMAIC-Six sigma process Improvement Approach

Process Improvement begins with ‘‘Thinking

Big’’ and ‘‘Starting Small’’ If it can’t be thought, it can’t be done.

Six Sigma-Process Improvement Approach

Six Sigma Introduction

DMAIC

Key activities in DMAIC phases

Simobo-Case study

Maryam Rehmat Process Engg.

Page 4: DMAIC-Six sigma process Improvement Approach

Six Sigma –Process Improvement Approach

Introduction to Six Sigma

Maryam Rehmat Process Engg.

What is Six Sigma?

Six Sigma is a proven, data-driven suite of improvement

methodologies based on a common philosophy

supported by measurement and tools for process and

product Improvement.

Page 5: DMAIC-Six sigma process Improvement Approach

Philosophy Behind

Six sigma philosophy states that defects can be eliminated by reducing

variations.

Reduced variations mean:

• Improved Customer satisfaction

• Reduced operating costs

• Increased profitability

Maryam Rehmat Process Engg.

Page 6: DMAIC-Six sigma process Improvement Approach

Sigma Level

It is, where a process or product performance falls when compared to

customer specification.

Table of levels with DPMO

Maryam Rehmat Process Engg.

Page 7: DMAIC-Six sigma process Improvement Approach

Primary Goals of Six Sigma

The quest to reduce variation consists of two primary goals to be

achieved in the following sequence:

1. Reduce Spread: Increase process precision or reduce variation

2. Center the process: Increase process accuracy

Maryam Rehmat Process Engg.

Page 8: DMAIC-Six sigma process Improvement Approach

Improvement Methodologies

DMAIC: for process improvement by reducing process variation

and defects.

Design for Six Sigma: for designing new processes and products

Lean Six Sigma: for improving process efficiency and speed.

DFSS DMAIC

LSS

Six Sigma

Maryam Rehmat Process Engg.

Page 9: DMAIC-Six sigma process Improvement Approach

What is DMAIC?

A problem solving method that is a roadmap which can be used for any

projects or quality improvements that needs to be made.

Maryam Rehmat Process Engg.

Page 10: DMAIC-Six sigma process Improvement Approach

Why DMAIC?

This methodology should be used when a product or process is in

existence at your company but is not meeting customer specification or

is not performing adequately.

Maryam Rehmat Process Engg.

Page 11: DMAIC-Six sigma process Improvement Approach

Question arises:

Why is DMAIC suitable for our environment?

Because:

We have processes BUT don’t know how are we doing with’em

So, We want to know,

Are we meeting our customer specifications?

If YES then to what extent ?

Where do our processes lay?

Maryam Rehmat Process Engg.

Page 12: DMAIC-Six sigma process Improvement Approach

What are DMAIC phases ?

Maryam Rehmat Process Engg.

Page 13: DMAIC-Six sigma process Improvement Approach

D- DEFINE THE PROBLEM.

The Define Phase is the first phase of the Six Sigma improvement

process. In this phase, the leaders of the project create a Project

Charter, create a high-level view of the process, and begin to

understand the needs of the customers of the process.

Maryam Rehmat Process Engg.

Page 14: DMAIC-Six sigma process Improvement Approach

MEASURE- MAP OUT THE CURRENT

PROBLEM

In the Measure Phase, the team focuses on data collection. They have

two goals:

• Determine the start point or baseline of the process and

• Find clues to understand the root cause of the problem in the process.

Maryam Rehmat Process Engg.

Page 15: DMAIC-Six sigma process Improvement Approach

ANALYSE-IDENTIFY THE CAUSE OF THE

PROBLEM

In the Analyze Phase, data collected during the Measure Phase is

reviewed.

Both the data and the process are analysed, in an effort to narrow down

and verify the root causes of waste and defects.

Maryam Rehmat Process Engg.

Page 16: DMAIC-Six sigma process Improvement Approach

In the Improve Phase, the team moves on to solution development.

A structured improvement effort can lead to innovative and elegant

solutions.

IMPROVE- IMPLEMENT AND VERIFY THE

SOLUTION

Maryam Rehmat Process Engg.

Page 17: DMAIC-Six sigma process Improvement Approach

CONTROL- MAINTAIN THE SOLUTION

In the Control Phase, the team begins to document exactly how they

want to sustain improvements by passing process improvement

infrastructure on to the employees who work within the process.

Maryam Rehmat Process Engg.

Page 18: DMAIC-Six sigma process Improvement Approach

DMAIC Overview and Simobo

Case Study Demonstration

Arooj Un Nisa Process Engg.

Page 19: DMAIC-Six sigma process Improvement Approach

D

Key activities in the Define phase are:

Define the problem statement or improvement opportunity in a way that

effectively

articulates why the Six Sigma project is necessary and why it is

necessary right now.

Develop the project charter.

Map the current process.

Gather the voice of the customer (VOC).

Form the project team.

Arooj Un Nisa Process Engg.

Page 20: DMAIC-Six sigma process Improvement Approach

M

Key activities in the Measure phase are:

Identify the measurements to collect

Develop and execute the measurements collection plan

Develop and validate the measurement system

Identify baseline performance measurements DPMO and sigma

level

Arooj Un Nisa Process Engg.

Page 21: DMAIC-Six sigma process Improvement Approach

A

Key activities in the Analyze phase are:

Stratify data to identify the underlying problem(s).

Identify root causes.

Validate root causes.

Arooj Un Nisa Process Engg.

Page 22: DMAIC-Six sigma process Improvement Approach

I

Key activities in the Improve phase include the following:

Identify potential solutions.

Evaluate and select potential solutions.

Arooj Un Nisa Process Engg.

Page 23: DMAIC-Six sigma process Improvement Approach

C

Key activities in Control phase include the following:

Pilot potential solutions (if needed).

Evaluate pilot results (if applicable).

Develop the control plan.

Develop the change implementation plan.

Develop procedures, standards, and training material.

Deliver training.

Communicate improvements.

Implement improvements.

Arooj Un Nisa Process Engg.

Page 24: DMAIC-Six sigma process Improvement Approach

PROJECT CHARTER TITLE Managing and Enhancing Quality of our Product Simobo by reducing the number

of support issues and non-conformities.

BUSINESS CASE The IT industries have a lot of work in their domain but the satisfied customers

are achieved only by High Quality Products

This can only be achieved by

o Increased Quality Service Time

o Reducing Cost (Development and Maintenance)

PROBLEM STATEMENT Confiz Solutions is committed to provide cost effective and efficient solutions to

their customers. This can be achieved by Enhancing Quality of Simobo by reducing

the number of support issues and non-conformities

OBJECTIVES Reduction in Number of Support Issues and Defects

METRICES Correctness, which is measured by Defect Density

Defect Density = (number of Defects/size of product in LOC ) * 100

SCOPE Development and maintenance of Simobo.

PROJECT SCHEDULE o Define Phase

o Measure Phase

o Analyze Phase

o Improve Phase

o Control Phase

PROJECT MEMBERS o Maryam Rehmat

o Arooj Un Nisa

Define Phase Activities performed on Simobo

Page 25: DMAIC-Six sigma process Improvement Approach
Page 26: DMAIC-Six sigma process Improvement Approach

Supplier input process output customer

Development team

Design team

QA team

I.T team

Client

Requirements

Design

specifications

PSD’S

Code

1. Domain Ramp up

2. Requirement

Analysis

3. Insight to Design

specifications

4. UI Testing

5. Functional testing

6. Integration testing

7. Defect logging

8. Defect verification

9. Defect closing

10. Defect responding

Defects/Bugs

Build Status Report

Features

Developer

I.T team

SIPOC

Page 27: DMAIC-Six sigma process Improvement Approach

KPI’S AND KPO’S

KEY PROCESS INPUTS KEY PROCESS OUTPUTS

Qualification Defect Density

Experience

Bugs

LOC

Arooj Un Nisa Process Engg.

Page 28: DMAIC-Six sigma process Improvement Approach

MEASURE PHASE-PARETO CHART

Arooj Un Nisa Process Engg.

Page 29: DMAIC-Six sigma process Improvement Approach

CAUSE AND EFFECT DIAGRAM

Arooj Un Nisa Process Engg.

Page 30: DMAIC-Six sigma process Improvement Approach

HISTOGRAM

Arooj Un Nisa Process Engg.

Page 31: DMAIC-Six sigma process Improvement Approach

PROBABILITY PLOT

Arooj Un Nisa Process Engg.

Page 32: DMAIC-Six sigma process Improvement Approach

CURRENT SIGMA LEVEL

Arooj Un Nisa Process Engg.

Page 33: DMAIC-Six sigma process Improvement Approach

Process Capability

Arooj Un Nisa Process Engg.

Page 34: DMAIC-Six sigma process Improvement Approach

ANALYSE PHASE

TESTING OF HYPOTHESIS

Our company is facing some support issues and we want to decrease

these support issues to 5% so for this we have to hypothesize:

Null Hypothesis:

Support issues are >=5%.

Alternate hypothesis:

Support issues are< 5%.

Arooj Un Nisa Process Engg.

Page 35: DMAIC-Six sigma process Improvement Approach

IMPROVE PHASE DESIGN OF EXPERIMENTS

Arooj Un Nisa Process Engg.

Page 36: DMAIC-Six sigma process Improvement Approach

Arooj Un Nisa Process Engg.

Page 37: DMAIC-Six sigma process Improvement Approach

Arooj Un Nisa Process Engg.

Page 38: DMAIC-Six sigma process Improvement Approach

CONTROL PHASE FMEA (Failure Mode and Effect Analysis)

Pro

cess

Step

Potential Failure Mode Potential Failure Effect SEV Potential Causes OCC Current Controls DET RPN Actions recommended Resp.

Do

mai

n

Ram

p u

p

Missing features Poor quality app 10 Wrong time estimates 1 Increased no of resources 0 0 Add cushion time in estimates,

Start domain ramp up at requirement elicitation

phase

Usman

Req

uir

emen

t

An

alys

is

Missing requirements Design is not according to

requirements

6 Negligence,

No Requirement

documentation

1 Increased no of resources 0 0 Involve QA at this stage

Document requirements properly

Aymen

Insi

ght

to

Des

ign

Spec

ific

atio

ns

No traceability of

requirements

Cosmetic defects in App 9 PSD’s not

provided/overlooked

1 Requirements mapped manually 0 0 Make sure to provide PSD’s in domain ramp up Aymen

UI T

esti

ng

Incomplete elements

exploration

Poor user interface with low

usability

8 Negligence

Test scenarios missing

2 Reviews by mentors 1 16 Trainings

Aymen

Fun

ctio

nal

Test

ing

Incomplete Requirement

Analysis

Non confirming products 10 Time bounds

Neglecting

Requirements/feature

1 Increased resources

Reviews by mentors

2 20 Prepare Requirement traceability matrix

Aymen

Inte

grat

ion

Test

ing

Incomplete product Customer dis-satisfaction 10 Incomplete domain ramp

up/feature exploration

2 Increased resources 3 60 Prepare Sanity checklist Aymen

Def

ect

logg

ing

Defects not logged/

Ambiguous Description

Incomplete fixation 5 Lack of

training/communication

issues

1 Unit testing

Increase resources

0 0 Comm. Skills Training Aymen

Def

ect

Ve

rifi

cati

on

Ripple effect/ regression

testing missing

Bugs in App 8 Negligence

No time for Halo testing

1 Cross check by other resource

Increased resources

0 0 Correct estimates for testing of a sprint/build Aymen

Def

ect

clo

sin

g

Closed without verification defective product 9 Time bounds

Negligence

1 Verification by Pm 0 0 Review after build or sprint Aymen

Def

ect

Reo

pen

ing

Reopened without verification Development overhead

resource wastage

6 Incomplete testing

Misunderstanding

1 Verification by Pm and Unit testing

by Dev.

0 0 Review after build Aymen

Page 39: DMAIC-Six sigma process Improvement Approach

Arooj Un Nisa Process Engg.

Page 40: DMAIC-Six sigma process Improvement Approach

Arooj Un Nisa Process Engg.

Page 41: DMAIC-Six sigma process Improvement Approach

Little Cast-Sigma Level

Defects

Opportunities Total Units DPU DPO DPMO Yeild Sigma Level

284 7 8445 0.033629366 0.0048042 4804.195 0.9951958 4.089612921

Arooj Un Nisa Process Engg.

Page 42: DMAIC-Six sigma process Improvement Approach

Thank You !