DMAIC can be applied in a highly automated environment. However, some of the tools that you may need are non-traditional to Six Sigma.
I would start out any automation DMAIC process by doing a pre-measure phase – validating the repeatability, accuracy and reproduceability of all measurement systems. What I’ve tended to see in many manufacturing environments is that the measurement systems (scales, feeders, weigh belts, thermocouples, etc) arent always installed correctly, maintained properly or scaled according to the range of operation. I would bet that you’d be able to make substantial improvements just by identifying measurement issues. I’d also take a long hard look at your data collection system. Is your data historian sampling fast enough? Do you have the capability to extract a years worth of data?
From there I’d go straight into define. It’ll be important that you scope correctly. Will IT infrascructure be within project scope? Whats your estimated saving? Do you have industry benchmarks available to establish entitlement? These are the questions you need to be asking.
Your analyze and improve phases may be slightly different depending on the volume of data you’re collecting. Fast Fourier Transform analysis may be more beneficial than a traditional DOE or multi-vari studies.
In short – yes, you can use DMAIC in a highly automated process.
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