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INDUSTRIAL ENGINEERING

    Manufacturing DMAIC Example – How Does DMAIC Work in Reality?

    Manufacturing DMAIC Example – How Does DMAIC Work in Reality?

    DMAIC, which stands for Define, Measure, Analyze, Improve, and Control, is a systematic approach used in Lean and other improvement management initiatives.

    How do we solve an actual problem using DMAIC?

    Read More

    1. DEFINE THE PROBLEM STATEMENT

    Identify the problem statement we are looking to solve.

    EXAMPLE:
    Problem Statement: “On all Welder Shifts throughout the year, Welders must spend time setting up their workstation, gathering tools, waiting on the tool crib checkout process. This adds waste into the process and prohibits welders from doing their work more efficiently. The required tools to do the job are not available as needed.”

    Problem Statement Template

    2. MEASURE THE PROCESS

    Are we able to provide metrics or data to support our problem statement? Include these in the Measure (M) Phase of DMAIC.

    EXAMPLES OF METRICS:
    Cycle Times
    Wait Times
    Current List of Tools
    Future List of Tools

    3. ANALYZE THE PROCESS

    Using the Problem Statement in Step 1 and the Metrics in Step 2, determine the largest wastes in the process. Perform a Process Map, identify all 7 Wastes throughout the process. For every waste, make a corresponding opportunity or improvement to correct the Waste.

    Example Value Stream Mapping Event in manufacturing

    4. IMPROVE THE PROCESS

    Using the identified Improvements and opportunities in Step 3, start to develop and plan action items. Utilize the Impact vs Effort Tool to rank and prioritize action items based on value created.

    Impact and Effort Curve for Lean Tools

    5. CONTROL THE OUTCOMES

    Monitor the improvements, perform data analysis for verification to ensure our metrics have improved.

    Conclusion:
    DMAIC offers a simple but effective way to map a process and analyze wastes to improve key performance metrics within a build. Using this real world example, see if you can improve one of your processes.

    AUTHOR

    Marcus Rosati

    B.S. Industrial Engineering – Purdue University
    B.S. Industrial Management – Purdue University

    Lead Industrial Engineer for Process Improvement Projects

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