Six Sigma DMAIC Roadmap

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he Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology can be thought of as a roadmap for problem solving and product/process improvement. Most companies begin implementing Six Sigma using the DMAIC methodology, and later add the DFSS (Design for Six Sigma, also known as DMADV or IDDOV) methodologies when the organizational culture and experience level permits. You can read the main differences between DMAIC and DMADV, but we'll focus on the DMAIC in this article.

While the DMAIC methodology presented below may appear linear and explicitly defined, it should be noted that an iterative approach may be necessary -- especially for Black Belts and Green Belts that are new to the tools and techniques that make up DMAIC. For instance, you may find that upon analyzing your data (Analyze phase) you did not gather enough data to isolate the root cause of the problem. At this point, you may iterate back to the Measure phase. In addition, prior knowledge of the tools and techniques is necessary in determining which tools are useful in each phase. Remember, the appropriate application of tools becomes more critical for effectiveness than correctness, and you don't need to use all the tools all the time.

DMAIC Phase Steps Tools Used D - Define Phase: Define the project goals and customer (internal and external) deliverables. Define Customers and Requirements (CTQs) Develop Problem Statement, Goals and Benefits Identify Champion, Process Owner and Team Define Resources Evaluate Key Organizational Support Develop Project Plan and Milestones Develop High Level Process Map Project Charter Process Flowchart SIPOC Diagram Stakeholder Analysis DMAIC Work Breakdown Structure CTQ Definitions Voice of the Customer Gathering Define Tollgate Review M - Measure Phase: Measure the process to determine current performance; quantify the problem. Define Defect, Opportunity, Unit and Metrics Detailed Process Map of Appropriate Areas Develop Data Collection Plan Validate the Measurement System Collect the Data Begin Developing Y=f(x) Relationship Determine Process Capability and Sigma Baseline Process Flowchart Data Collection Plan/Example Benchmarking Measurement System Analysis/Gage R&R Voice of the Customer Gathering Process Sigma Calculation Measure Tollgate Review A - Analyze Phase: Analyze and determine the root cause(s) of the defects. Define Performance Objectives Identify Value/Non-Value Added Process Steps Identify Sources of Variation Determine Root Cause(s) Determine Vital Few x's, Y=f(x) Relationship Histogram Pareto Chart Time Series/Run Chart Scatter Plot Regression Analysis Cause and Effect/Fishbone Diagram 5 Whys Process Map Review and Analysis Statistical Analysis Hypothesis Testing (Continuous and Discrete) Non-Normal Data Analysis Analyze Tollgate Review I - Improve Phase: Improve the process by eliminating defects. Perform Design of Experiments Develop Potential Solutions Define Operating Tolerances of Potential System Assess Failure Modes of Potential Solutions Validate Potential Improvement by Pilot Studies Correct/Re-Evaluate Potential Solution Brainstorming Mistake Proofing Design of Experiments Pugh Matrix House of Quality Failure Modes and Effects Analysis (FMEA) Simulation Software Improve Tollgate Review C - Control Phase: Control future process performance. Define and Validate Monitoring and Control System Develop Standards and Procedures Implement Statistical Process Control Determine Process Capability Develop Transfer Plan, Handoff to Process Owner Verify Benefits, Cost Savings/Avoidance, Profit Growth Close Project, Finalize Documentation Communicate to Business, Celebrate Process Sigma Calculation Control Charts (Variable and Attribute) Cost Savings Calculations Control Plan Control Tollgate Review

As you can see, the power of the Six Sigma DMAIC methodology lies in the structure and the rigor. Of the hundreds of TQM tools that have been developed over the years, the most important ones (described above) are taught in detail by consultants to Black Belts and Master Black Belts.

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