Six Sigma Black Belt Study Guides - PMTUTOR14)_Overview_of_DMAIC.pdf · Six Sigma Black Belt – Study Guides . ... Cp, cpk Pp, ppk Cpm Process performance ... SWOT analysis Outputs

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Six Sigma Black Belt –

Study Guides


Overview of Six Sigma DMAIC Process

Define – Define the project targets and customer (internal and external)

deliverables.

Measure – Measure the process to determine the current process performance

baseline).

Analyze – Find out the root causes of the defects.

Improve – Improve the process by eliminating defects.

Control – Control the future performance.


Define

Inputs

Important stake

holder

Business Need

/ Business

Case

Tools and Techniques

Benchmarking

Market research data

Historical quality

information

Team experience

Quality Function

Deployment

CTQ flow down

Kano customer satisfaction

levels

Customer value analysis

Outputs

VOC

KPI

Balance

scorecard

Financial

measures


Define

Inputs

VOC

KPI

Balance

scorecard

Financial

measures


Charter negotiations

Templates

Expert judgment

Decomposition

GANTT chart

CPM & PERT

Outputs

Project charter

Performance

metrics

WBS

Network

diagrams

Project

management

plan and

baselines


Measure

Inputs

Network

diagrams

Project

management

plan and base

lines

Project charter

Performance

metrics


Business process

management

SIPOC

Process maps and

flowcharts

Outputs

Processes

Process

characteristics

Process flow

metrics

Process inputs

and outputs


Measure

Inputs

Processes

Process

characteristics

Process flow

metrics

Process inputs

and outputs


Ishikawa diagrams

Relational matrices

Prioritization matrix

Outputs

Current

process

performance


Measure

Inputs

Continuous and

discrete data

Process

characteristics

Process flow

metrics

Process inputs

and outputs


Measurement scale

Data integrity and

accuracy

Prioritization matrix

Data collection methods

Check sheets

Coded data

Automated gauging

Outputs

Sampling

strategies

Error

frequencies


Measure

Inputs

Continuous and

discrete data

Process

characteristics

Process flow

metrics

Process inputs

and outputs


Measuring instruments

Gauge R and R study

Control chart method

Calibration systems

Outputs

Measurement

systems

analysis

Measurement

correlation

Measurement

error

Gauge

Acceptance

criteria


Measure

Inputs

Continuous and

discrete data

Process

characteristics

Process flow

metrics

Process inputs

and outputs


Descriptive (Enumerative)

statistics

Population parameters and

sample statistics

Central limit theorem

Central tendencies

Stem-and-leaf plots

Box and Whisker

plots

Histograms and

frequency polygons

Probability plots

Run chart

Scatter diagram

Outputs

Frequency

distributions

Measures of

dispersion


Measure

Inputs

Continuous and

discrete data

Process

characteristics

Process flow

metrics

Process inputs

and outputs


Inferential (analytical) statistics

Probability

Mutually exclusive

Independent

Conditional

Combinations,

permutations

Continuous distributions and

probability distribution

functions

Uniform

Normal

Bivariate normal

Lognormal

Exponential

Weibull

Chi-square

Student’s t

F

Discrete distributions and

mass functions

Binomial

Poisson

Hypergeometric

multinomial

Outputs

Frequency

distributions

Measures of

dispersion


Measure

Inputs

Continuous and

discrete data

Process

characteristics

Process flow

metrics

Process inputs

and outputs


Process capability studies

Sigma level – short term

and long term

Outputs

Cp, cpk

Pp, ppk

Cpm

Process

performance

metrics

DPU

PPM

DPMO

FPY

RTY

COPQ


Analyze

Inputs

Measurement

systems

Process

capability

indices

Process

parameters

affecting CTQs

Process

performance

metrics

Cost of poor

quality (COPQ)


Failure Mode and Effect

Analysis (FMEA)

Tree diagram

Gap analysis

Root cause analysis

Five Whys

Pareto Chart

Fault tree analysis

Cause-and-effect

analysis

Outputs

Potential

causes of

defects

Risk Priority

Number (RPN)

Corrective

action to be

taken

Comparison of

current and

future state

Value added

and non-value

added

activities


Analyze

Inputs

Validating

potential

causes


Testing of hypothesis

Point and interval

estimation

Biased / Unbiased

estimator

Confidence intervals

Null / alternative

hypothesis, type 1 and

type 2 error, power of a

test

Test for means,

variances, and

proportions (one sample

and two sample)

Goodness of fit test

ANOVA (One-way

ANOVA and Two-way

ANOVA)

Non-parametric tests

Outputs

Validated

causes


Analyze

Inputs

Validating

potential

causes


Correlation and regression

analysis

Variables and

relationships

Correlation

coefficient

Simple linear

regression model

Method of least

squares

Residuals

Simple linear

regression

hypothesis testing

(Test for correlation

coefficient, slope

parameter)

Sources of variation

Coefficient of

determination

Multiple linear

regression

Outputs

Relationships

between

variables

Best fitted and

validated

model


Analyze

Inputs

Potential

causes of

defects

Non-value

added activities

Validated

causes


Kanban

Poka-Yoke

5S

Standard operations

(work)

Kaizen and Kaizen

Blitz

SMED

Continuous flow

manufacturing (CFM)

Theory of constraints

(TOC)

Outputs

Waste

elimination

Cycle-time

reduction

Decreased

inventory

Decreased

operating

expenses


Improve

Inputs

Potential

causes of

defects

Non-value

added activities

Validated

causes


Design of experiment

(DOE)

DOE terminologies

DOE planning

process

Types of

experiment designs

Interaction

One factor

experiments

Completely

randomized one

factor experiments

Randomized block

experiments

Latin square designs

Yales order

Fractional factorial

experiments

Outputs

Identification of

best solution

(through

experimentation)

for

implementation


Improve

Inputs

Identification of

best solution

(through

experimentation)

for

implementation


Pilot runs

Simulations

Models

Prototypes

Implementation

strategies

Risk analysis and

mitigation

Scenario

planning

FMEA

SWOT analysis

Outputs

Implementation

plan


Control

Inputs

Identification of

solutions for

implementation

Implementation

plan


Statistical process control

(SPC)

Special and common

cause of variation

Rational sub-

grouping

Variable control

charts (X-bar and R,

X-bar and s, I-MR)

Attribute control

charts (p, np, u, c)

CUSUM chart

MAMR chart

Total productive

maintenance (TPM)

Lean tools (5S, visual

factory, Kaizen, Kanban,

Poka-yoke)

Outputs

Implemented

solutions


Control

Inputs

Implemented

solutions


Measurement system

improvement

Measurement

system analysis

(MSA)

Process capability

analysis

Graphical data

analysis

Statistical testing

Process audit

Product audit

Internal audit

Outputs

Revised

measurement

system

Control plan for

sustaining

benefits

Improved

process

capability

Lessons

learned

Training plan

deployment

Documentation


Overview of Six Sigma DMAIC Process

Conclusion

DMAIC at a glance

Inputs – Tools and Techniques – Outputs

Documents

Six Sigma Black Belt Study Guides - PMTUTOR14)_Overview_of_DMAIC.pdf · Six Sigma Black Belt – Study Guides . ... Cp, cpk Pp, ppk Cpm Process performance ... SWOT analysis Outputs