DMAIC Approach

Define Phase
Project is initiated and defined. Project Charter is created, includes: business case, problem statement and the scope of project. Project management is determined
Measure Phase
Data and processes examined IOT understand them. Measurement systems are developed. Current process performance is measured. Key performance indicators for that process are determined. Data is collected – Amount of defects and variation is determined.
Analyze Phase
Brainstorm and identify potential causes of problem. Relationships between inputs, processes and outputs identified. Waste is determined and theories developed for potential root causes. How current baseline processes work is determined. Root causes verified = cause and effect.
Improve Phase
Solutions are generated based off root causes. All potential solutions are evaluated through data-driven exercises. Risks are assessed and error-proofing exercises put in place. Pilot plans are conducted and implementation occurs.
Best solution based on
Criteria developed by business. Feasibility & implementation-ability of solution.
Control Phase
Long term capabilities are verified. Statistical process control and control plans determined to ensure process will continue to be measured. Processes should be standardized to avoid falling back to old ways. Improvements quantified for report out.
Tollgate Meetings: Who?
The Black Belt, sponsor, possibly Green belt, possibly Team member
Sponsor’s role
Provide guidance to help the team. Keep team on target and prevent distraction. Provide staff, funding, requests for additional team members, etc. Make team clarify and verify things.
Tollgates of Define Phase
1. Project Charter
2. Customer needs and requirements
3. Map the Process
Project charter (Tollgate 1)
Tollgate 1. Create the business case, problem statement and define scope of project. Keep both effectiveness (defects) and efficiency (speed and waste) in mind.
Customer needs and requirements (Tollgate 2)
Tollgate 2. Define what customer wants. Review against Lean concept of ‘value’
Map the process (Tollgate 3)
Tollgate 3. Understand the process that delivers the product or service. Utilize value stream map from lean tool set
Tollgates of Measure Phase
4. Performance indicator identification
5. Data collection plan
6. Baseline performance measurement
Performance indicator identification (Tollgate 4)
Tollgate 4. Select the metrics. Base metrics on process mapping. Upstream indicators and critical Xs. Focus on cycle time and defects.
Data collection plan (Tollgate 5)
Tollgate 5. Thoroughly operationalize the data. Generate: operational definitions, types of data, sampling plan & costs of gathering data.
Baseline performance measurement (Tollgate 6)
Tollgate 6. Verify the need for the project and describe project impact. Gather process capability information and determine sigma levels. Use tools to enhance lean approach (cycle time, lead time, quality, etc)