Lean Six Sigma Fundamentals Isee - 582 / 682: Measure Phase

Lean Six Sigma
Fundamentals
ISEE – 582 / 682
Lecture 12
Measure Phase
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Measure Phase
 A key question to answer in the Measure Phase centers on how the
process currently performs.
• What is the magnitude of the problem?
• How bad is it?
 As the team starts collecting data they focus on the process as well
as what customers care about. That means initially there are two
major targets: reducing lead time or improving quality.
 During the Measure Phase, the team refines the definitions of each
measure and determines the current performance—the baseline—of
the process.
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How does the Process Currently Performs?

 Teams must establish the current state of the process
before considering changes.
 The baseline becomes the standard against which the
team assesses the impact of their solutions.
• This is a key step since the team must eventually compare the data
collected during the Measure Phase against the data collected during
the Improve Phase to confirm there is actual improvement.
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Create a Plan to Collect the Data

 Once the team clarifies the baseline measure
• Must consider where to get the data
• How much to collect
• Who will get it and how.
 A well-thought-out Data Collection Plan is critical since
accurate and reliable data are key to good decision making.
 This plan is prepared for each measure and includes helpful
details such as the operational definition of the measure as
well as any sampling plans.
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Data
Collection
Plan
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Data needs to be Reliable

 Data collection generally involves gathering system
information, creating reports and manually collecting
process information when it’s not readily available.
 The team creates tracking mechanism for the manually-

collected data and continues until they have a reliable
data set to establish the baseline.
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Data Collection Plan

 Step 1: Identify the Questions we want to answer.
• Our data must be relevant to the project. What is your project’s

hypothesis? What are we trying to answer? The entire reason to have a
DMAIC project is to improve a process so these questions should be
centered around what the reality of your process is. And that’s best
discovered by defining the current state.
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 Step 2: What kind of data is available?
• Now we break those questions down into their parts. What data exists
that can give us these answers – or part of these answers.
• Sometimes a particular piece of data can give us multiple answers.
• Sometimes we need to explore that data in relation to other data.

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 Step 3: What form does that data come in?
• Determine what Type of data we are measuring. Create a Data

Collection Form.
• Is it continuous data or discrete?
• If the data is continuous, use a histogram or a run chart.
• If attribute, use Pareto chart or pie chart

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 Step 4: How Much Data Do We Need?
• We want to get enough data so what we can see patterns and trends.
For each data element on the list write down how much is needed.
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 Step 5: How are we going to measure this data?
• Data can be measured in different ways; check sheets, survey answers, etc. The
way we measure will be dependent upon the kind of data we seek.
• Decided on an operational definition for each measurement.
• Identify the specification of the measurement. (Should be based on the customer’s

limits of acceptability.)
• Define the target values (And what direction do we want the process to go in?)
• Put a real, objective value for each target.

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 Step 6: To Sample or Not to Sample
• Sometimes it is impractical to measure an entire population of data and

instead you have to take a sample. How much do you need to sample
of the parent population to make statistically-sound judgements?
• How are you going to sampling the data?
• How will you avoid measurement bias?

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 Step 7: How will we display the data?
• We can display data in many ways; control charts, pareto diagrams, run
charts, etc.
• Which graphical display tool is best suited to answer our questions?

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Data
Collection
Plan
Example
Form
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Data Collection – CAUTION!

 Systems with archives of data often have flaws, or the data only occurs infrequently.
 Data collection takes time from operators and management and can be viewed as a burden.
 Finding the balance to get as much information as possible that is proven reliable while not
consuming excessive resources is key to success in this phase.
 This data collection will often encounter resistance and can lead to the temptation of taking
the easier routes, rounding off numbers, or otherwise skewing and creating inaccuracies.
 Education, awareness, rule setting, and up front discussion with all stakeholders (not just
team members) is necessary to get the most cooperation and validity in data collection.
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Measurement System Analysis (MSA)

 Uses scientific tools to determine the amount of
variation contributed by the measurement system
 Objective to assess validity of measurement system and
minimize factors contributing to process variation
• Process Variation
• Appraiser Variation
• Total Measurement System Variation
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Measure
System
Analysis
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Measurement System Analysis (MSA)

 The following components of measurement error need to
be studied and quantified before establishing process
capability and making decisions from the data.
• ACCURACY / BIAS
• RESOLUTION / DISCRIMINATION
• LINEARITY
• STABILITY
• REPEATABILITY & REPRODUCIBILITY (Gage R&R)
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Measure
System
Analysis
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Update Project Charter

 Initial data collection efforts provide the team with
helpful details around process performance and
potential targets.
 The team refines their Project Charter with new data that
more accurately reflects the problem and the goal.

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Lean Six Sigma

How does the Process Currently Performs?

Create a Plan to Collect the Data

Data needs to be Reliable

 The team creates tracking mechanism for the manually-

Data Collection Plan

• Our data must be relevant to the project. What is your project’s

Data Collection Plan

• Sometimes a particular piece of data can give us multiple answers.

• Sometimes we need to explore that data in relation to other data.

Data Collection Plan

• Determine what Type of data we are measuring. Create a Data

• Is it continuous data or discrete?

• If the data is continuous, use a histogram or a run chart.

• If attribute, use Pareto chart or pie chart

Data Collection Plan

Data Collection Plan

• Decided on an operational definition for each measurement.

• Identify the specification of the measurement. (Should be based on the customer’s

• Put a real, objective value for each target.

Data Collection Plan

• Sometimes it is impractical to measure an entire population of data and

• How are you going to sampling the data?

• How will you avoid measurement bias?

Data Collection Plan

• Which graphical display tool is best suited to answer our questions?

Data Collection – CAUTION!

Measurement System Analysis (MSA)

Measurement System Analysis (MSA)

Update Project Charter

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