Sample Q\'s & Answers - 6 Sigma (DMIAC) PDF

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Lecturer: T O'Kane
These are past questions and answers for the 6 Sigma (DMIAC) topic...

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6-Sigma - DMAIC Question: (a) The 6-Sigma DMAIC process framework is widely used throughout industry for process improvement. Describe the DMAIC framework, paying particular attention to the activities that take place during each phase. (40 percent)

1. Introduction:    

6 Sigma focuses on measuring the quality of a process in terms of the number of defects it 6-Sigma initiatives seek to reduce variation in business processes by identifying and then removing the causes of defects 6-Sigma reduces variability using the DMAIC framework In this answer, I will outline: o The input and outputs of the process – x and y factors o The DMAIC process itself o And finally the major roles in the process

Example:  

An example of 6-Sigma in real terms using surgery as an example. A surgery process with a value of 3-Sigma would mean there would be 1,350 poorly performed surgeries in 1 week. Compare that to the same process except with a value of 6-sigma would mean there would be only 1 poorly performed surgery in 20 years

2. Define, Measure, Analyse, Improve, Control – DMAIC    

One of the main frameworks used by 6-Sigma to reduce variability is the DMAIC framework This is mainly used on improving existing processes As part of the DMAIC process, factors are outlined that go into the completion of the process – X and Y factors Outlined below are the factors, the DMAIC process itself and the major roles in the framework

6-Sigma - DMAIC X and Y Factors: -

Y factors refer to outcomes or results desired from the process X factors refer to inputs that could result in the production of Y

Big Y Factors: -

These are the most important business results and measures that are linked to critical customer requirements and expectations

Little Y Factors: -

These refer to operational objectives that must be improved to achieve ‘big Y’ improvements E.g. in a restaurant the ‘big Y’ might be to improve dinner satisfaction and the ‘little Ys’ could be time to seat customers, availability of menu choices

Big X Factors: -

These are input factors or variables that have the most impact on the ‘Big Y’

Little X Factors: -

Sub factors that influence a ‘big X’ E.g. in delivering a pizza, traffic, weather, delivery driver all influence the delivery time

DMAIC Process: 1. Define Phase: 

Define the problem, the voice of the customer and the project goals 1. Poorly performing areas are identified and prioritised through use of data 2. Gather and prioritise customer wants and need (their voice) 3. Make a business case for improvement 4. Form teams and issue charter 5. Map the process

2. Measure Phase: 

Measure key aspects of the current process and collect relevant data 1. Identify the set of metrics that need to be collected to characterise the process 2. Prioritise metrics 3. Identify how the data will be collected 4. Identify how data will be validated 5. Make use of quality control tools like  Check sheets  Pareto charts  Cause and effect (Ishikawa) diagrams  Histograms

6-Sigma - DMAIC 3. Analyse Phase: 

Analyse the data to investigate and identify causes and effects 1. When, where and why do defects occur i.e. understand exactly what is happening within a process and why defects are occurring 2. Look from both process and data perspectives 3. Use appropriate statistical tools 4. Characterise the defect 5. Go after root cause

4. Improve Phase: 

Improve or optimise the current process 1. Generate solutions or mistake proof processes 2. Weigh up costs and benefits 3. Select the best solution 4. Understand the risks 5. Pilot the new process 6. If successful – plan for implementation

5. Control Phase: 

Control the new process to ensure that any deviations from target are corrected before they result in defects 1. Assign a process owner 2. Document the process 3. Use statistical process control (SPC) tools to control the process 4. Continuously monitor the process 5. Seek process change for further improvements 6. Monitor the results

Key Roles in DMAIC: Project Champion: 

Involved in o Selecting projects o Identifying Black and Green Belt candidates o Setting improvement target o Providing resources o Reviewing the projects on a regular basis o Removing any road blocks to the program success

Master Black Belt: 

Involved in: o Technical leaders of 6 Sigma o Serve as instructors for Black and Green Belts

6-Sigma - DMAIC o o o

Provide ongoing coaching and support to project teams to assure the appropriate application of statistics Help Project Champions Deploy 6 Sigma program

Black Belts: 

Are: o o o o o o o

Backbone of 6 Sigma deployment Highly qualified Lead teams Attack chronic problems Manage projects ‘Drive’ teams for solutions that work Responsible for bottom line results

Green Belts:    

Provide team support to Black Belts Assist in data collection, input Analyse data using software Prepare reports for management

Yellow Belts:    

Represent large percentage of workforce Trained with basic skills Assist GB and BB on large projects Assist in build and sustain 6 Sigma culture

White Belts:    

Foot-soldiers in a project work force Basic 6-sigma overview training Not regarded as core competency for them Work under direction

3. Conclusion

6-Sigma - DMAIC Question: (b) Despite its widespread adoption 6-Sigma has been criticized. Briefly outline some of these criticisms (10 percent)

Answer: 1. Lack of Originality   

Quality expert, Juran - “Nothing new” Basic approach to process improvement Flamboyant terms – “master black belt”

2. Overselling by Consultancies 

Many consultancies falsely claim expertise in 6 Sigma

3. Arbitrary standards   

6 Sigma is limited in processes it can improve Other products/services may need higher levels that 6 Sigma E.g. cardiac pacemakers, autopilot software

4. Stifling Creativity:  

Overreliance on metrics, steps and measures stifles workers’ ability to innovate Intense focus on variability reduction waters down discovery process...