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The next step is to validate the solution(s) identified through a pilot run or through
optimization design of experiments.
After confirmation of the improvement, then a detail project plan and cost benefit
analysis should be completed.
The last step in this phase is to implement the improvement. This is a point where
change management tools can prove to be beneficial.
7.8.5
Phase 5: Control
The Control phase consist of four steps, In the first step, we determine the control
strategy based on the new process map, failure mode and effects, and a detailed
control plan. The control plan should balance between the output metric and the
critical few input variables.
The second step involves implementing the controls identified in the control plan.
This typically is a blend of poka yoke's and control charts as well as of clear roles
and responsibilities and operator instructions depicted in operational method sheets.
Third, we determine what the final capability of the process is with all of the
improvements and controls in place.
The final step is to perform the ongoing monitoring of the process based on
the frequency defined in the control plan. The DMAIC methodology has allowed
businesses to achieve lasting breakthrough improvements that break the paradigm of
reacting to the causes rather than the symptoms. This method allows design teams
to make fact-based decisions using statistics as a compass and to implement lasting
improvements that satisfy the external and internal customers.
7.9
DMAIC SIX SIGMA TOOLS
The DMAIC is a defined process that involves a sequence of five phases (define,
measure, analyze, improve, and control). Each phase has a set of tasks that get
accomplished using a subset of tools. Figure 7.14 (Pan et al., 2007) provides an
overview of the tools/techniques that are used in DMAIC.
Most of the tools specified in Figure 7.14 above are common across Six Sigma
projects and tend to be used in DMAIC-and DFSS-based projects. Some additional
ones are used and will be explored in Chapters 10 and 11. Many statistical needs
(e.g., control charts and process capability) specified in the tools section are available
through Minitab (Minitab Inc., State College, PA).
The DMAIC methodology is an acronym of the process steps. Although rigorous,
it provides value in optimizing repeatable processes by way of reducing waste and
making incremental changes. However, with increasing competition and the human
resources needed to rework a product, there is a greater need to bring out products
that work correctly the first time around (i.e., the focus of new product development
is to prevent defects rather than fixing defects). Hence, a DFSS approach that is the
next evolution of the Six Sigma methodology often is used in new product initiatives
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