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Six Sigma Project Checklist

 

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Six Sigma Project Checklist This Six Sigma Project Checklist is created to explain this famous business management strategy (initially invented by Motorola) to business managers who are interested in implementing it. Using this checklist you can study two methods included in it – DMAIC and DMADV.


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DMAIC (the method utilized for existing business processes):

  1. Define:
    • DMAIC method is used to solve a problem with an unknown solution. On this step you need to choose a problem area and define the problem in clear measurable terms;
    • Create Problem Statement;
    • Identify the Processes involved and map them;
    • Identify and consider the voice of the customer (define the customers and their needs);
    • Identify Champion;
    • Identify Process Owner;
    • Determine Customers and their Requirements (CTQs – Critical To Quality characteristics);
    • Assemble your Six Sigma Team (specifically trained managers within a company who are responsible for quality improvement project and titled as “Black Belts”, “Green Belts”, etc);
    • Define project Goals;
    • Calculate business impact and state metrics;
  2. Measure:
    • Define the key aspects of the current process (CTQs received from customers become points of critical priority);
    • Develop and implement data collection plan;
    • Collect relevant data on the process;
    • Describe the current state of the process;
    • Determine key process output variables (they are called Y’s);
    • Map the Process in its current state;
    • Determine the initial capability and stability of the project Y’s;
    • Measure Y’s;
    • Define the potential ways for process and its inputs to go wrong (use FMEA – Failure Modes and Effects Analysis);
  3. Analyze:
    • Analyze the information gathered;
    • Carry out design of experiments to understand how process variables affect process results;
    • Determine performance gaps and define performance goals (for Y’s);
    • Approve cause-and-effect relationships;
    • Analyze Y’s through MSA (Measurement System Analysis);
    • Define wasted and non-wasted actions;
    • Perform Variance Component Analysis for Y’s;
    • Figure out the Sources of Variation;
    • Seek out root cause of the defects;
    • Benchmark best practice (Y’s);
    • Identify key drivers (X’s);
    • Determine the major X’s and Y=f(x) Relationship;
    • Perform Measurement System Analysis for X’s;
  4. Improve:
    • Develop improvement hypotheses and link them with potential solutions;
    • Study process capability improvement;
    • Define accepted tolerances and assess failure modes of potential solutions;
    • Characterize and optimize the process as required;
    • Approve and validate potential improvement via Pilot implementation;
    • Verify process capability improvement;
    • Test and amend hypotheses;
  5. Control:
    • Develop validate monitoring and control system;
    • Develop and update control plans, standards and procedures;
    • Establish control charts for X’s;
    • Create workflow specifications, explain operating tolerances and train participants;
    • Put in place statistical process control and mistakes proofing;
    • Monitor business metrics to make sure the process achieves a higher level of results;

DMADV (the method for creating new product or process designs):

  1. Define design goals coming from customer demands and aligned with the enterprise strategy;
  2. Measure:
    • CTQ’s;
    • Product Capabilities;
    • Production Process Capability;
    • Risks;
  3. Analyze to develop:
    • Design alternatives to reduce defects;
    • A high-level design;
    • Design capability;
  4. Design Details:
    • Optimize the design to work at its peak;
    • Plan for design verification;
    • Simulations and modeling;
  5. Verify:
    • The Design conception through...


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