Boutique product development company It is amazing what you can accomplish when you have a client-centric team to deliver outstanding products.
May 20, 2015
Boutique product development company It is amazing what you can accomplish when you have a client-centric team to deliver outstanding products.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
What are DMAIC phases ?
Maryam Rehmat Process Engg.
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.
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.
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.
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.
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.
DMAIC Overview and Simobo
Case Study Demonstration
Arooj Un Nisa Process Engg.
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.
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.
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.
I
Key activities in the Improve phase include the following:
Identify potential solutions.
Evaluate and select potential solutions.
Arooj Un Nisa Process Engg.
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.
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
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
KPI’S AND KPO’S
KEY PROCESS INPUTS KEY PROCESS OUTPUTS
Qualification Defect Density
Experience
Bugs
LOC
Arooj Un Nisa Process Engg.
MEASURE PHASE-PARETO CHART
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CAUSE AND EFFECT DIAGRAM
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HISTOGRAM
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PROBABILITY PLOT
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CURRENT SIGMA LEVEL
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Process Capability
Arooj Un Nisa Process Engg.
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.
IMPROVE PHASE DESIGN OF EXPERIMENTS
Arooj Un Nisa Process Engg.
Arooj Un Nisa Process Engg.
Arooj Un Nisa Process Engg.
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
Arooj Un Nisa Process Engg.
Arooj Un Nisa Process Engg.
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.
Thank You !