Basic DMAIC Problem Solving

Course Description:
This course is specifically designed to meet the analytical needs of people working
within a variety of industries. This course is designed for those individuals working
directly on product and process development and corrective / preventative action.
It is assumed they come from a variety of backgrounds and disciplines and will be
working on a variety of process improvement areas across the company. The course
is designed for 16 hours of presentation.

Attendees:
This course is required for all scientists, engineers and quality professionals who
actively work on all aspects of discovery, product and process development where
the goal is to understand the root cause of performance problems and implement
appropriate CAPA procedures to assure the problem never occurs again.

 

Course Objectives:
Upon completion of the course the participants will be able to:

  1. Identify a problem that requires action.
  2. Define a problem in measurable terms.
  3. Contain the problem while developing a durable solution.
  4. Measure core performance and establish metrics.
  5. Collect and analyze data relevant to the problem of interest.
  6. Analyze the system of causes and determine root cause.
  7. Plan and implement corrective and preventative relevant to the
    root cause of the problem.
  8. Evaluate the effectiveness of the solutions.
  9. Establish controls to sustain solutions.
  10. Use Excel or JMP for basic statistics and data analysis.

Prerequisites:  None

Detailed Course Outline:

Introduction to Root Cause Analysis                                                 
Need for improvement
Savings associated with root cause analysis
Eight+ basic quality tools
                                                
Define and Contain the Problem
Define the problem
Contain the problem
Determine scope, objectives and goals
Project leadership and planning  
                         
Measure the Problem
Map the process
Determine data collection plan
Establish metrics and capability 
                                                     
Analyze Data and Determine Root Cause
Analyze and summarize the data
Analyze and summarize the process map
Determine root causes and summarize all findings     
                                                           
Improve Performance
Brainstorming solutions and CAPA
Benefit, cost, risk and complexity determination
Measuring solution effectiveness                
                                              
Control and Standardize Improvements
Process owner
Select controls