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project management steps in lean six sigma
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a concise explanation of the DMAIC approach
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Understanding the DMAIC Methodology for any process improvementDMAIC PROCESS
DMAIC is a general improvement method and is the backbone for six sigma hence the standard Six Sigma
improvement method which refers to —Define, Measure, Analyze, Improve, and Control.
DMAIC PROCESS is a process improvement step and its application is primarily limited to improving
existing processes.
Normally, the process to improve is made up of dependent and independent variables. an independent
variable is a factor that impacts another related factor called a dependent variable. For instance, exercise
(or manufacturing process) is an independent variable (X) because it affects another variable called body
weight (or defects), a dependent variable (Y). In testing, the independent variable (X) is allowed to change
in a systematic manner, and its effect on the behavior of a dependent (controlled) variable (Y) is studied.
Y is also called an output variable. So, output Y is dependent on X
Y = f(x)
Define: This stage allowed us to Understand the project output Y and how to measure it. This stage
deploys a project charter and SIPOC diagram. Create a project charter that will govern efforts moving
forward and use SIPOC to identify stakeholders and customers, define a process through process mapping.
The team could as well use the VSM and voice of the customer to describe the situation at hand.
Measure: here, we identify the potential Xs (independent variable) and measure Xs and Y. The team must
have to get more data as much as possible in this stage of the DMAIC process. Some of the tools often
deployed in the Measure phase are the CTQ tree and sigma level calculation. The team can start using
FMEA to identify risk priorities for various inputs and errors within a process as well as Box Plots, Pareto
Chart to identify the impact of Xs on Y.
Analyze: Determine X–Y relationships and, after verification, quantify important Xs. Here basically we use
different tools depending on the data to explore the insight of the data from the measure phase. Some of
the tools used here include Box Plots, Pareto Chart, The Cause and Effect (or Fishbone Diagram), 5 whys
correlation coefficient, regression analysis & etc. of which all these tools help in determining important
Xs that have effect on the Y.
, Improve: Devise solutions to optimize Xs to improve Y. The team uses brainstorming to provide possible
solutions for the root causes identified in the analyze phase and rank those solutions according to costs,
how effective the solution would be, and how likely the solution could be implemented. Since this stage
is to optimize, one could use any applicable optimization tools like linear and integer programming as
well as design of experiment.
Control: Control and monitor important Xs and the output Y over time. Is the last stage of a DMAIC
process. During this control phase, teams build monitors that let them ensure the process continues to
work successfully after the changes are implemented across the regular business process. Typically, the
team uses control plan, statistical process control, 5S and poka yoke as the eye to monitor the process
over time.
DMAIC TOOLS
PROCESS
DEFINE Project charter, SIPOC, VOC, VSM, SWIMLANE Map, A3, 5 whys ,Activity network
diagrams, Advanced quality planning, Affinity diagrams, Auditing, Benchmarking,
Brainstorming, Cause-and-effect diagrams, Check sheets, Communication plan, Control
charts, Critical-to-quality (CTQ) tree, Customer feedback, Customer identification,
Customer interviews, Data collection, Data collection plan, Failure mode and effects
analysis (FMEA), Flowchart/process mapping, (as is) Focus groups, Force field analysis
Gantt chart, Interrelationship digraphs, Kano model, Matrix diagrams, Meeting minutes,
Multi-voting, Nominal group technique, Pareto charts, Project evaluation and review
technique (PERT), Prioritization matrix Process, decision program chart, Project charter,
Project management, Project scope, Project tracking, Quality function deployment
(QFD), Run charts, Sampling Stakeholder analysis, Supplier–input–process– output–
customer (SIPOC), Tollgate review, Tree diagrams Y=f(X)
MEASURE Basic statistics, Brainstorming, Cause-and-effect diagrams, Check sheets, Circle
diagrams, Correlation Data collection, Data collection plan, Failure mode and effects
analysis (FMEA), Flowcharts, Gage R&R Graphical methods, Histograms, Hypothesis
testing, Measurement systems analysis (MSA), Meeting minutes, Operational
definitions, Pareto charts, Probability, Process capability analysis, Process flow metrics,
Process maps, Process sigma, Project management, Project tracking Regression. Run
charts, Scatter diagrams, Spaghetti diagrams, Statistical process control (SPC), Supplier–
input–process– output–customer (SIPOC), Taguchi loss function, Tollgate review, Value
stream maps
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