FAKULTI TEKNOLOGI KEJURUTERAAN

ELEKTRIK DAN ELEKTRONIK

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

COMPUTER ENGINEERING WORKSHOP 1

BEEC1323 SEMESTER 1 SESI 2022/2023

LAB 3: 6 Sigma

NO. STUDENTS' NAME MATRIC. NO.

1. MUHAMMAD SHAIFUL AZIM BIN REDZUAN B082210049

2. NURUL AIN BINTI SHIKRONI B082210366

3.

PROGRAMME 1 BEEC

SECTION /
S1/2
GROUP

DATE 30 OCOTBER 2022

1. Ts EFEENDY ONN BIN SIAM

NAME OF
INSTRUCTOR(S)
2.

EXAMINER’S COMMENT(S) TOTAL MARKS

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Rev Date Author(s) Description
.
No.

1.0 30 JAN 1. Ahmad Nizamuddin 1. Update to new UTeM logo

2019 2. Update faculty's name
3. Change "course" to
"programme"
4. Remove verification stamp

2.0 26 OCT 2.Nurlliyana binti Abd 1. Modified Labsheet

2020 Mutalib

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1.0 OBJECTIVES

After completing this lab, students should be able to:

 Identify, select and use appropriate methods and tools to successfully complete
their assigned projects
 Demonstrate the understanding of DMAIC

2.0 EQUIPMENT
Nil

3.0 SYNOPSIS & THEORY

DMAIC

 DMAIC refers to a data-driven improvement cycle used for improving, optimizing

and stabilizing business processes and designs.
 DMAIC is the five-step approach that makes up the Six Sigma tool kit, and its sole
objective is to drive costly variation from manufacturing and business processes.
 Six Sigma in organization simply means a measure of quality that strives for near
perfection.
 Six Sigma is a business management strategy, originally developed by Motorola in
1986.
 Six Sigma seeks to improve the quality of process outputs by identifying and
removing the causes of defects (errors) and minimizing variability in
manufacturing and business processes. It uses a set of quality management
methods, including statistical methods, and creates a special infrastructure of
people within the organization ("Black Belts", "Green Belts", etc.) who are experts
in these methods.

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   The five steps in DMAIC are   Define, Measure, Analyze, Improve, and Control. 

D Define the problem, the voice of the customer, and the project goals, specifically
M Measure key aspects of the current process and collect relevant data
A Analyze the data to investigate and verify cause-and-effect relationships. Determine
what the relationships are, and attempt to ensure that all factors have been
considered. Seek out root cause of the defect under investigation
I Improve or optimize the current process based upon data analysis using techniques
such as design of experiments, poka yoke or mistake proofing, and standard work to
create a new, future state process. Set up pilot runs to establish process capability
C Control the future state process to ensure that any deviations from target are
corrected before they result in defects. Control systems are implemented such as
statistical process control, production boards, and visual workplaces and the process
is continuously monitored

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 Example :

Table 1: DMAIC in Mathematical Terms

Steps Phase Questions

1. Understand what process is to be Define  What is the Y or the outcome

improved and set a goal. measure?

2. Measure the current state. Measure  What is Y’s current

performance?

 What are the potential Xs or

3. Develop cause-and-effect theories of causes?
what may be causing the problem.  What may be causing the

Analyze problem?
4. Search for the real causes of the problem  What are the real Xs or causes?
and scientifically prove the cause-and-
effect linkage.  What is really causing the
problem?

 How can the understanding of

the real causes of the problem

Improve be exploited to eliminate or

5. Take action.
reduce the size of the problem?
 How can this Y = f(X)
understanding be exploited?

6. Measure to verify improvement has  Did Y really improve?

taken place.
Control
 How can the Xs be controlled
7. Take actions to sustain the gains. so the gains in Y remain?

In summary, Six Sigma DMAIC methodology is really just a series of common sense
questions that one asks in order to solve any problem and eventually sustain the gains that
come from solving the problem.

4.0 PROCEDURE

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Part A : DMAIC Tools

Lately the road accident seems to increase significantly in the Ayer Keroh industrial area,
and 40% out of the cases are classified as a fatal accident. Data shows, majority of the road
accident happen within 11pm to 6am time frame. This is reflects to the shift changing time
for the most manufacturing plants in the Ayer Keroh industrial area itself. Most victims are
among the industrial workers. Surveys data below, shows some of the causes which
possibly can leads to the road accident in this area.

No. Causes Count

1 Sleepy 22
2 Speeding 18
3 Bad road condition 6
4 No light / dark at junctions area 13
5 Traffic lights malfunction happen very often 5
6 Motorist not wear a safety helmet 2
7 slippery road 8
  Total 74

You will represent your company and other several team members which are come from
other companies in the Ayer Keroh industrial area to form an Industrial Response Team
and will cooperate with the PDRM to reduce the road accident in this area. Using the
DMAIC approaches, kindly find the solution on how to reduce the rate of the road
accidents especially the fatal cases in this industrial area.

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 Part B : Demonstrate the understanding of DMAIC

Study the diagram below. Identify the problem.

From the diagram, you need to fill in the DMAIC table to summarize your understanding.

5.0 DISCUSSION AND CONCLUSION

Write what you learn from this workshop.

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 PART A: DMAIC TOOLS
DEFINE - Cause of increasing road accidents in Ayer Keroh
industrial area.
- Improvements in traffic and law enforcement, increase
road and lighting quality.
- To reduce the road accidents in Ayer Keroh industrial
area.
- Most victims are among the industrial workers.
MEASURE - The current safety level at this area is at a Red Area.
- The success capability of this process is high.
- Start as soon as possible and stop when problem has been
controlled.
- Increase fine for traffic offender, improve road condition,
increase road lamp quantity and arrange periodic
inspection on traffic lights.
ANALYZE - The main causes of the road accident came from own
carelessness, then followed by bad road and traffic
facilities condition,
- This was proven when the count of accident due to sleepy,
speeding and motorist not wearing safety helmet is 48
while the count of road accident caused by bad quality of
road and traffic facilities is 26

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IMPROVE

CONTROL - Sample Plan table as below:-

cause action Implementation time
sleepy - don’t drive Immediately
when our body
is tired
- spread
awareness
about “ the risk
of microsleep”
speeding -increase the Immediately
fine for
breaking the
speeding limit
- adds more
speedtraps
Bad roads - put suitable Immediately
condition warning sign
at the bad road
area
-authorities
must taken
attentive in

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 making sure it
is safe to use
No light/dark - replace the Immediately
junction area broken street
light
- add more
street light
especially at
dark junction
area
Traffic light - authorities Immediately
malfunction should arrange
happen very a periodic
often inspection on
the traffic light
- drivers must
have self-
awareness with
the condition
of the road
Motorists not - authorities Immediately
wear a safety need to
helmet schedule a
routine
roadblock
- increase the
fine for not
wearing
helmet
Slippery road - put the Immediately
warning sign
- fine the
irresponsible
company who

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spill industrial
waste such as
chemical fluid
and oil

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PART B: DEMONSTRATE THE UNDERSTANDING OF DMAIC

PROBLEM PHASE QUESTION

- Economy Define - What is
- Performance of the outcom
Organization e
- Organizational culture measure
- Job characteristics ?
- Unrealistic employees
expectation
- Personal reasons
- Availability of higher Measure - What is
paying obs the
- If organization is current
struggling financially, compan
workers may seek other y’s
employment for security perform
- Reward system, strength ance?
of leadership
- Challenge, danger
- Job not clearly explained
during interview process
- Family situation

- Economy – Employees
are underpaid - What
- Performance of Analyze are the
organization – bad potentia
management system l of
- Organizational culture - employ
favoritism among ees
employees in the turnover
company. causes?
- Job characteristic – - What
Employees can burnt out may be
easily due to causing
overwhelming the
challenges, afraid of problem
high risk job such as ?
handling a dangerous
machines and working
at high places.

- Unrealistic employee
expectations –
employers did not
explain specific job
scope during the

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 interview process
- Personal reason –
unavoidable family
problem such as chronic
diseases that needs
continuous medical
attention from the
family.
- Employers can offer the higher Improve - How
salary can the
- Reorganization the understa
organization with the caliber nding of
staff. the real
- Treats employees equally. causes
- Give the job scope that suitable of the
with their qualification. problem
- Employers should provide be
safety training before exploite
employees start working. d to
- Employers should clarify about eliminat
the job specifically e or
- Company needs to be more reduce
considerate with the employees the size
with personal reason. of the
problem
?
Control - Did it
really
improve
?

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 - Above is the Sample
Plan to improve the
Employees Turnover
problem.

DISCUSSION AND CONCLUSION

- What we get during completing task, this method is to improve the

efficiency and effectiveness of organization progress. This method is
collecting and analyze the data given, then split into their phase such as
define, measure, analyze, improve and control. In conclusion, Six Sigma
can be a powerful and strategic methodology to consistently measure
results, which can then become a new baseline for improved
performance.

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