DMAIC Phase Steps Tools Used

D – Define Phase: Define the project goals and customer (internal and external) deliverables.

 Define Customers and Requirements (CTQs)  Project Charter

 Develop Problem Statement, Goals and Benefits  Process Flowchart
 SIPOC Diagram
 Identify Champion, Process Owner and Team
 Stakeholder Analysis
 Define Resources
 DMAIC Work Breakdown
 Evaluate Key Organizational Support Structure
 Develop Project Plan and Milestones  CTQ Definitions
 Develop High Level Process Map  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  Process Flowchart
 Develop Data Collection Plan  Data Collection Plan/Example
 Benchmarking
 Validate the Measurement System
 Measurement System
 Collect the Data Analysis/Gage R&R
 Begin Developing Y=f(x) Relationship  Voice of the Customer Gathering
 Determine Process Capability and Sigma Baseline  Process Sigma Calculation

Measure Tollgate Review

A – Analyze Phase: Analyze and determine the root cause(s) of the defects.

 Histogram
 Pareto Chart
 Time Series/Run Chart
 Scatter Plot
 Regression Analysis
 Cause and Effect/Fishbone
Diagram
 5 Whys
 Define Performance Objectives  Process Map Review and Analysi
 Identify Value/Non-Value Added Process Steps  Statistical Analysis
 Identify Sources of Variation  Hypothesis
 Determine Root Cause(s) Testing (Continuous and Discrete
 Determine Vital Few x’s, Y=f(x) Relationship  Non-Normal Data Analysis

Analyze Tollgate Review

I – Improve Phase: Improve the process by eliminating defects.

 Perform Design of Experiments  Brainstorming

 Mistake Proofing
  Develop Potential Solutions  Design of Experiments
 Define Operating Tolerances of Potential System  Pugh Matrix
 Assess Failure Modes of Potential Solutions  QFD/House of Quality
 Failure Modes and Effects
 Validate Potential Improvement by Pilot Studies
Analysis (FMEA)
 Correct/Re-Evaluate Potential Solution  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  Process Sigma Calculation
Growth  Control Charts (Variable and
Attribute)
 Close Project, Finalize Documentation
 Cost Savings Calculations
 Communicate to Business, Celebrate  Control Plan

Control Tollgate Review