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?

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.”

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.

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

May 20, 2024

INDUSTRIAL ENGINEERING