Putting the AI in DM-AI-C

Industry: Not Industry Specific

Keywords: Artificial Intelligence, DMAIC, Tools

Level: All Levels

"The Lean Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) process has long proven itself as the most successful systematic, data-driven approach for process improvement. Lean professionals are always on the lookout to improve their craft; this presentation offers ways that AI technologies can be integrated into the DMAIC method to increase our efficiency, accuracy, and decision-making.

As early as the Define phase, we find AI opportunities, where natural language processing (NLP) and Chatbot technologies can help us pick trends and salient points out of volumes of customer feedback, from survey responses to customer complaint logs. AI flexes its muscle even more during the Measure phase. In the era of Big Data, we can tap into huge volumes of data from ERP and operations data systems; but we can easily get lost when faced with these mountains of data. AI neural networks can perform data cleansing on these huge data sets, freeing us to focus on the underlying trends.

Where AI can make its biggest impact, though, is in the Analyze and Improve phases. During root cause analysis, AI can identify complex patterns within data and pinpoint the underlying causes of process issues. Process mining tools can analyze event data to create visual representations of processes, helping us to see cause-and-effect relations using visual mediums so useful for project teams. During the Improve phase, AI optimization algorithms can identify the best set of parameters for improved processes. For example, they can optimize manufacturing processes to maximize output while minimizing resource usage. We can use Genetic Algorithms to determine the optimal arrangement of process steps (such as the location of machines and workers on the plant floor) given a set of constraints provided by the project team, based on critical customer requirements (CCRs).

Finally, teams can insert AI tools directly into the subject process as part of process Control. Many commercial systems are already available, including vision systems for quality control (perhaps the most mature of the AI technologies in processes).

This presentation will provide Lean Six Sigma practitioners with great application ideas, based on existing systems already in the field. We will also take a peek into the future to help you stay on top of these rapidly evolving technologies so that you can apply DM-AI-C faster and better than ever."

How You Can Apply AI Today

Industry: All Industries

Keywords: AI, ChatGPT, DMAIC

Level: Advanced

Artificial Intelligence tools, especially Large Language Models like ChatGPT, dramatically change how we approach our jobs.

⦁ How can a practicing Black Belt use these tools to improve processes faster and more effectively?

⦁ What are good examples of the types of AI tools most applicable to process improvement?

⦁ Where does AI fit in the DMAIC process?

Let's enjoy this champagne networking session as we dive into the possibilities.

Don Johnston

Director, Getzler Henrich & Associates LLC, Titusville, FL, USA

As a Master Black Belt with engineering and management backgrounds, Don Johnston applies Lean principles and systems modeling to increase capacity, speed performance, reduce operating cost, and improve quality.

He has worked in manufacturing, maintenance, engineering, supply chain, and services operations in industries such as aerospace, automotive, distribution, apparel, and food. In addition to traditional process improvement and lean six sigma implementations, Don has applied advanced analytical techniques such as replenishment pull, genetic algorithms, Monte Carlo simulations, and discrete event modeling to optimize operations and reduce inventory.

Don holds a Mechanical Engineering degree from MIT and a Masters in Engineering Management from Florida Tech. He is a certified Master Black Belt in Lean Six Sigma and has trained hundreds of Black Belts and Green Belts.