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PDCA or Deming Cycle

v PDCA was an iterative process continually improving the products, peoples and services

v First, proposed by Walter Shewhart and later developed by William Deming, the PDCA
cycle became a widespread framework for constant improvements in manufacturing,
management, and other areas.

Use the PDCA cycle when:

• Starting a new improvement project
• Developing a new or improved design of a process, product, or service
• Defining a repetitive work process
• Planning data collection and analysis in order to verify and prioritize problems or root causes
• Implementing any change
• Working toward continuous improvement

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 Why Why Analysis | 5 Why analysis method with example

Root Cause of Problems

▪ Problems happen every day and it is up to Industrial Engineers to understand why!
▪ Problems are not solved properly unless you understand why they are occurring.
▪ The reason for a problem is called the problem’s root cause.
▪ The root cause can be found by utilizing a method called the 5 whys.

5 Why Method

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 → "Why-Why" analysis is an analytical method that is

designed to help you identify all factors contributing to a

problem one by one in an orderly fashion, rather than a hit-

and-miss attempt to work out the factors and finally, we will

→ have the root

"Why-Why" cause
analysis foranalytWhat
is an the failure.
is Why Why ANALYSIS?

ical method that is designed to help you identify all factors contributing to a problem one by one in an orderly fashion, rather than a hit-and-
→ If Root cause not eliminated or fixed the problem will
miss attempt to work out the factors and finally, we will have the root cause for the failure.
reccurs continiously repeats

→ Sakichi Toyoda developed this technique and firstly used

it within the Toyota Motors.

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→I

5
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→

→ Ask "why" till the root-cause is determined.

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q DMAIC is a structured and disciplined problem-solving methodology that can be applied to a wide

range of industries and situations beyond just Six Sigma.

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The key benefit of using DMAIC outside of Six Sigma is that it provides a standardized and

data-driven approach to problem-solving that can be applied in any industry or situation.

By using DMAIC, organizations can identify and address the root causes of problems,

improve processes, and achieve better outcomes, regardless of whether they are formally

practicing Six Sigma or not.

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 : Collate what we already know about the existing process.

: Collect further data about the existing process.

: Identify the core problems that we’ll address.

: Plan, test, and implement solutions.

: Set up supports to ensure that successful solutions are

sustainable.

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 DMAIC - Define
BUSINESS CHARTER

Business Case: Opportunity Statement:

• To increase Nesting Efficiency Nesting Efficiency Low
• To Reduce scrap % Scrap % Increased
• To improve 5'S 5'S Affected
• To Reduce Raw Material % Visual Factory Affected
• To eliminate end bit laser cutting. Increase in end bit and storage issues.
WIP affected.
ACETECH

Goal Statement: Project Scope:

Y = To standardisation of cut to lenght sheet In Scope:
size AMC - Violet Bay
Out of Scope:
X1 = Raw Material Cut to Length Other Bays
X2 = MBQ

Project Plan:
Project selection:
Kick off :
Project time line : 12 weeks
SEE NEXT SLIDE
17th day report out : Material Planned for cut to
length
35th Day report out : Required process completed
&Material Purchased.

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Identify the data that you need to collect.

Decide what measurements to use.

Figure out what methods to use to collect your measurements.

Determine the level of variation that you’ll be dealing with.

Collect the data as per previous points.

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→ The purpose of the Measure step in project is to create a complete picture of the current
process state and establish current baselines.

→ To identify the baseline Project

→ Use this baseline for setting the target as an improvement.

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Ø Use measure data to identify the probable causes of the problem

Ø Identify the actual root cause using brainstorming, 5 why, and other techniques

Ø Find the critical root cause that has the highest impact on CTQ

Ø Verify the root causes using appropriate statistical tools and techniques like

hypothesis testing

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Analyze phase in DMAIC:
→ The purpose of this stage is to identify all possible causes and then find out the root
cause or causes.
➨ Activities of the Analyze phase
→ Analyze the Data
→ The data analyzing method is depending on the type of data collected.
→ Identify Causal Factors
→ Find out a valid root cause or causes by brainstorming.
→ The Fishbone Diagram (Cause & Effect Diagram) is also used to find out the root cause.
→ Another popular and effective method for root cause determining is 5 Why method 21
→ Scatter Diagram is also used for validation activity
→ The purpose of this stage is to identify all possible causes and then find out the root cause or

causes.

➨ Activities of the Analyze phase

→ Analyze the Data

→ The data analyzing method is depending on the type of data collected.

→ Identify Causal Factors

→ Find out a valid root cause or causes by brainstorming.

→ is also used to find out the root cause.

→ Another popular and effective method for root cause determining is 5 Why method

→ Scatter Diagram is also used for validation activity

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The benefits of process map analysis:
• Increase the understanding of a process
• Analyze how a process can be improved
• Improve communication among the individuals engaged in the same process
• Provide process documentation
• Plan projects effectively.
The tools for process map analysis:
• Brainstorming
• Plan-Do-Check-Act cycle(PDCA cycle)
• FMEA(Failure Mode and Effect Analysis)
• Fishbone diagram
• SIPOC

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➨

→ Identify Potential Solutions

→ Analyze the cost-benefit analysis of the implementation of the solution.

→ By Brainstorming, the team should identify possible improvements that would increase efficiency and improve
product quality.

→ Analyze Failure Modes of Proposed Solutions

→ Failure Modes and Effects Analysis (FMEA) is often completed before the implementation of any changes.

→ The FMEA helps the team identify and address potential failure modes that may arise due to the improvements in
the system or in the operation sequence.

→ Validate Improvements

→ Validation may be tested on prototype builds or on simulations.

→ Estimate the financial gains.

→ Validate the updated operation flow.

→ Develop a Risk Mitigation Plan and Process Control Plan.

→ Implement the solution as per planning

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→ In this step, the team checks the sustainability of the changes were made during the project.

→ Update Documentation like Standard operating procedures (SOP's), Control plan, Development
plans, Process Maps, Work Instructions, Visual Aids, etc.

→ Give training to all associate about the changes were made during the project.

→ Communicate about the updated roles and responsibilities.

→ Implement Statistical Process Control (SPC)

→ Create a Process Monitoring Plan

→ Celebrate the successful completion of the project with the team and top management.

→ Ensure an ongoing Process Monitoring Study is working properly.

→ Communicate to Business Results & sign off to close the Six Sigma Project

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