DMAIC-v2: A Novel Guide to the Improvement of Industrial Processes

Abstract

Abstract This paper introduces DMAIC-v2, an enhanced approach based on the Six Sigma Define, Measure, Analyze, Improve, and Control (DMAIC) methodology aimed at facilitating the improvement of industrial processes in a more efficient and effective manner. DMAIC-v2 expands upon the capabilities of the classic DMAIC to address a wider range of applications effectively and efficiently, including modern equipment and processes. This updated version introduces an innovative methodology for evaluating improvement options by leveraging modeling and simulation techniques. It also incorporates a real-time quality control model for optimizing the effectiveness of quality control in production processes and output products. Furthermore, it introduces an innovative approach for programming and controlling industrial processes using augmented reality, virtual reality, and digital twin technologies. To showcase the effectiveness of DMAIC-v2, this paper presents a case study focusing on the improvement of a twisting system for automotive cables. The case study demonstrates how DMAIC-v2 is effective in reducing variability, minimizing the waste of raw materials, and enhancing the characteristics of the product. This paper serves as a practical guide for improving industrial equipment and production processes to achieve higher-quality products. It provides a roadmap and effective methods for addressing challenges related to industrial processes, including equipment variability, lack of flexibility and smartness, budget constraints, waste of raw materials, and product quality. By following the recommendations presented in this paper, firms can overcome these challenges and enhance their overall performance.