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What tools are needed for a Lean deployment using the DMAIC method?
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Most of the time, when people ask for a definition of Lean, the answer given is often a list of tools, which in no way reflects the approach.
Knowledge and mastery of Lean tools is central, but knowing how to make the right diagnosis is also vital. The two work together and are inseparable.
In this article, we’ll look at the DMAIC method and its appropriate tools. The list of tools provided is not exhaustive, but will help you find your way around and adapt it to your situation.
The DMAIC process combines the concept of diagnosis with the use of associated tools, enabling activities to be ordered on the basis of data collected, while using tools specific to each stage of the method.
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Step 1: Define
The tools used for this stage will make it possible to :
– Defining the scope and limits of the project and the project team
– Map the process in order to study it, identify the influencing factors and identify the various flows.
– Summarise and formalise customer requirements
The tools :
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- The project charter : A document issued by the project sponsor containing the information needed to bring the project to a successful conclusion.
- VOC – Voice of Customer : It’s an information-gathering tool used to identify customer needs.
- SIPOC – Suppliers-Inputs-Process-Outputs-Customers This will enable you to identify the perimeter on which you need to act.
- VSM – Value Stream Mapping This tool allows you to map the process in its initial state.
- Flow chart Schematic representation of process activities.
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Step 2: Measure
The Measure stage is a data compilation stage, and the tools used will enable :
– Measure customer satisfaction parameters and the process factors that influence them
– Collecting data
– Analysing the data
The tools :
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- Analyse des flux : C’est un outil graphique qui simplifie un processus opérationnel en éliminant toutes les étapes inutiles. C’est une méthode de collecte de données basée sur l’observation sur le terrain.
- Capability : Capability is a method of measuring the ability of a machine, process or measuring device to achieve a required performance.
- Pareto chart : This is an analysis tool for determining the importance of different phenomena.
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Step 3: Analyse
For this stage the tools are used to :
– Make the data collected and the process analyses speak for themselves
– Identify the root causes of malfunctions
– Determine the variables and their causes
The tools :
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- Brainstorming: This is a formalised technical method for creative and collective problem solving.
- 5M: This is a method of finding causes based on 5 themes: manpower, machine, environment, method, material.
- FMEA – Failure Modes, Effects and Criticality Analysis : This predictive risk analysis method is based on the identification, analysis and evaluation of potential failures in the system under study.
- Benchmarking : This is an approach designed to compare the company, its organization and its processes with its partners and, in the best of cases, with its competitors.
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Stage 4: Innovation
The Innovate stage allows the implementation of the solution(s) to move from theory to practice:
– Confirm the assumptions made in the Analyse phase
– Implementing improvement solutions
– Check the effectiveness of the solution(s)
The tools :
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- The standard: This is a tool for focusing on added value, without waste, by using the best known way of performing a task at a given time.
- Design of experiments : The aim of design of experiments is to study the influence of modifying different parameters on the same process.
- VSM – Value Stream Mapping Cible : This tool enables you to map your target process, highlighting the improvement projects needed to achieve it.
- QQOQCP – Who? Who? Where? When? How? Why? It’s a questioning method based on the use of Who, What, Where, When, How and Why questions to identify a situation.
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Step 5: Check
The tools used in this stage are used to :
– Communicating objectives
– Check that the project is running smoothly
– Maitriser les changements
The tools :
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- Visual management: This is a tool for communicating information visually, helping to clear up misunderstandings, save time and highlight drifts.
- Performance indicators: A tool for assessing the achievement of these objectives.
- Control cards A tool used to monitor and control a manufacturing process. The cards define control limits within the customer’s tolerances, and act as a warning system during production by taking and measuring samples.
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There are a number of other tools that can be used depending on your situation. The real added value is not in knowing as much as you can, but in knowing how to make the right diagnosis and how to select the tools that will enable you to uncover the bottlenecks, analyse the root causes and find solutions.
You will soon be able to find out more about the DMAIC method and the tools used for your Lean deployment in our Lean Academy, soon to be available on our TEEPTRAK website.
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