DMAIC Approach

Solving Technical Challenges in Plastic R&D

1. D

   Define

   Define the Problem

   • Understand the issue and customer impact
   • Gather VOC (Customer, Internal Stakeholders)
   • Define problem statement and scope
   • Set project goals and CTQs
2. M

   Measure

   Measure the Problem

   • Identify key process inputs and outputs
   • Collect data on materials, process and performance
   • Use analytical tools to understand current performance
   • Establish baseline and quantify the gap
3. A

   Analyze

   Analyze the Root Cause

   • Identify potential causes (Material, Machine, Method, Man, Measure, Environment)
   • Use data analysis, DOE, and testing to find root cause(s)
   • Validate root cause with experiments and evidence
4. I

   Improve

   Improve the Solution

   • Generate and screen solutions
   • Optimize formulation, process parameters and design
   • Validate improvements through trials and testing
   • Ensure performance, quality and cost effectiveness
5. C

   Control

   Control the Gains

   • Implement control plan and process monitoring
   • Standardize best practices and work instructions
   • Train team and ensure sustained performance
   • Continuously monitor and drive continuous improvement