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

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Six Sigma –Process Improvement
Approach
Introduction to Six Sigma

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.

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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

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Sigma Level

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

customer specification.

Table of levels with DPMO

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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

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Improvement Methodologies

Six Sigma

DMAIC DFSS LSS

 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.

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 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.

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 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.

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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?

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What are DMAIC phases ?

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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.

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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.

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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.

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IMPROVE- IMPLEMENT AND VERIFY
THE SOLUTION
In the Improve Phase, the team moves on to solution development.
A structured improvement effort can lead to innovative and
elegant solutions.

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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.

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DMAIC Overview and Simobo
Case Study Demonstration

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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.

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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

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A
Key activities in the Analyze phase are:

Stratify data to identify the underlying problem(s).

Identify root causes.

Validate root causes.

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I
Key activities in the Improve phase include the following:

Identify potential solutions.

Evaluate and select potential solutions.

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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.

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Define Phase Activities performed on
Simobo

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
SIPOC

Supplier input process output customer

 Development team  Client 1. Domain Ramp up  Defects/Bugs  Developer
 Design team Requirements 2. Requireme  Build Status Report  I.T team
 QA team  Design nt Analysis  Features
 I.T team specifications 3. Insight to
 PSD’S Design
 Code specifications
4. UI Testing
5. Functional
testing
6. Integration
testing
7. Defect logging
8. Defect
verification
9. Defect closing
10. Defect
responding
KPI’S AND KPO’S
KEY PROCESS INPUTS KEY PROCESS OUTPUTS

Qualification Defect Density

Experience

Bugs

LOC

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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

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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%.

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IMPROVE PHASE DESIGN OF EXPERIMENTS

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CONTROL PHASE FMEA (Failure Mode and Effect Analysis)
Process Step Potential Failure Mode Potential Failure Effect SEV Potential Causes OCC Current Controls DET RPN Actions recommended Resp.

Domain Ramp up Missing features Poor quality app 10 Wrong time estimates 1 Increased no of resources 0 0 Add cushion time in estimates, Usman
Start domain ramp up at requirement elicitation
phase

Requirement Missing requirements Design is not according to 6 Negligence, 1 Increased no of resources 0 0 Involve QA at this stage Aymen
Analysis requirements No Requirement Document requirements properly
documentation

Insight to Design No traceability of Cosmetic defects in App 9 PSD’s not 1 Requirements mapped manually 0 0 Make sure to provide PSD’s in domain ramp up Aymen
Specificatio ns requirements provided/overlooked

UI Testing Incomplete elements Poor user interface with low 8 Negligence 2 Reviews by mentors 1 16 Trainings Aymen
exploration usability Test scenarios missing

Functional Incomplete Requirement Non confirming products 10 Time bounds 1 Increased resources 2 20 Prepare Requirement traceability matrix Aymen
Testing Analysis Neglecting Reviews by mentors
Requirements/featur
e

Integration Incomplete product Customer dis-satisfaction 10 Incomplete domain ramp 2 Increased resources 3 60 Prepare Sanity checklist Aymen
Testing up/feature exploration

Defect logging Defects not logged/ Incomplete fixation 5 Lack of 1 Unit testing 0 0 Comm. Skills Training Aymen
Ambiguous Description training/communication Increase resources
issues

Defect Ripple effect/ regression Bugs in App 8 Negligence 1 Cross check by other resource 0 0 Correct estimates for testing of a sprint/build Aymen
Verification testing missing No time for Halo testing Increased resources

Defect closing Closed without verification defective product 9 Time bounds 1 Verification by Pm 0 0 Review after build or sprint Aymen
Negligence

Defect Reopening Reopened without verification Development overhead 6 Incomplete testing 1 Verification by Pm and Unit testing 0 0 Review after build Aymen
resource wastage Misunderstanding by Dev.
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Little Cast-Sigma Level

Defects Opportunities Total Units DPU DPO DPMO Yeild Sigma Level

28 7 844 0.03362936 0.004804 4804.19 0.995195 4.0896129

4 5 6 2 5 8 21

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Thank You !