[KEY] DMAIC (Six Sigma) Project Matrix Data Sheet

structured matrix data sheet for DMAIC (Six Sigma) projects, tailored for automotive/manufacturing quality improvement. It includes key phases, deliverables, tools, and metrics:

DMAIC (Six Sigma) Project Matrix Data Sheet

Project Title: [E.g., "Reducing Car Hood Paint Defects"]Team: [Cross-functional members]Date: [Timeline]

DMAIC Phase	Key Deliverables	Tools & Techniques	Data Metrics	Output Examples
Define (D)	- Project charter (SIPOC, VOC). - Stakeholder alignment.	- Voice of Customer (VOC). - SIPOC diagram.	- Baseline defect rate (e.g., 12% paint flaws). - Cost of poor quality (COPQ).	Goal: Reduce defects by 50% in 6 months.
Measure (M)	- Data collection plan. - Process maps.	- Check sheets. - MSA (Gage R&R). - Process capability (Cp/Cpk).	- Defect types/rates (Pareto chart). - Cycle time data.	Finding: 80% defects from primer contamination (MSA confirmed gauge accuracy).
Analyze (A)	- Root cause verification. - Statistical validation.	- 5 Whys. - Fishbone diagram. - Hypothesis testing (t-test, ANOVA).	- Correlation analysis. - RPN (if FMEA used).	Root Cause: Poor supplier primer storage (p<0.05 in ANOVA).
Improve (I)	- Pilot solutions. - DOE (Design of Experiments).	- Poka-yoke. - FMEA updates. - Simulation software.	- Pilot results (e.g., defect reduction to 4%). - Cost-benefit analysis.	Solution: New primer drying protocol + supplier audit.
Control (C)	- Standardized SOPs. - Control plan.	- SPC charts. - Control plans. - Training docs.	- Sustained defect rate (e.g., 3% ±0.5%). - CpK >1.33.	Sustained Result: Saved $180K/year, 6σ compliance.

Automotive-Specific Additions

1. IATF 16949 Alignment:

   • Control Plan: Maps inspection points to critical characteristics (e.g., hood thickness).

   • PPAP: Documents DMAIC changes for customer approval.

2. Critical Tools:

   • MSA: Ensures measurement accuracy for defects (e.g., paint thickness gauges).

   • DOE: Optimizes parameters (e.g., oven temp, spray pressure).

3. Metrics:

   • DPMO (Defects Per Million Opportunities).

   • FTY (First-Time Yield) for stamping/welding processes.

Example Data Inputs & Outputs

Phase	Input Data	Analysis Output
Measure	500 hoods inspected, 60 defects.	Pareto shows 70% defects from dust particles.
Analyze	Primer viscosity lab tests.	Low viscosity correlates with defects (R²=0.89).
Improve	Pilot batch with new primer.	Defects dropped to 8/500 (84% improvement).

Templates & Software

• Project Charter Template: [Link]

• SPC Chart (X-bar R): [Example]

• Software: Minitab (statistics), JMP (DOE), Power BI (dashboards).

Key Takeaways

• Data-Driven: Relies on statistical validation (e.g., p-values, CpK).

• Structured: Phases ensure thorough RCA and sustainable fixes.

• ROI Focused: Tracks cost savings (e.g., reduced scrap/rework).

Need a completed DMAIC example (e.g., Excel/PDF) or industry-specific KPIs