DMAIC Process Guide

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DEFINE
1 Define problem and
goal statements
BUSINESS CASE
Evaluate measurement
5 system, stability &
capability
BASELINE STUDY
ANALYZE
Review the results
1 of graphical & basic
analysis
PROCESS ANALYSIS
5 Confirm improvement
against baseline
OUTCOME VS. BASELINE
CONTROL
Prepare a control
1 plan and select
control methods 2 Standardize the solutions by
CONTROL MEASURES
Identify high
2 Define customer
needs 3 level process
map 4 Develop project
charter 5 Develop project
plan
CUSTOMER NEEDS HIGH LEVEL PROCESS CHARTER PROJECT PLAN
MEASURE
Establish Identify key
4 Collect data on the problem
and factors 3 a data
system 2 process input
variables 1 Create AS-IS
process map
DATA COLLECTION DATA SYSTEM KEY PROCESS VARIABLES AS-IS PROCESS STUDY
Verify root
2 Identify all potential
root causes 3 Narrow down potential
root causes 4 causes using
statistic 5 Create a
prediction model
CAUSES IDENTIFICATION ROOT CAUSE ANALYSIS CAUSES VERIFICATION MODELING
IMPROVE
Develop Evaluate, select and Generate solutions
4 Pilot and implement the
plan 3 Implementation
plan 2 optimize best
solutions 1 to eliminate root
causes & NVAs
IMPLEMENTATION PLAN IMPLEMENTATION SOLUTION SELECTION SOLUTIONS GENERATION
Transfer Prepare an audit
updating the SOPs 3 ownership to
process owner 4 Capture and share
realized benefits 5 process and set-up
a control dashboard
STANDARDIZATION HANDING OVER BENEFITS SHARING CONTINUOUS MONITORING
DEFINE
Benchma- Y=f(x) Quick
rking VOC QFD CTQ Cascade
COPQ PERT
Wins

Force Field Analysis Pareto Analysis Prioritization Kano Analysis KPIs SIPOC analysis VSM Stakeholder Analysis Project Charter Gantt Chart Risk Analysis

BUSINESS CASE CUSTOMER NEEDS HIGH LEVEL PROCESS CHARTER PROJECT PLAN

Process Mapping

MEASURE
Data
Capability Measles Operational Spaghetti
Study SPC MSA Sampling Collection Definition Diagram
Chart Plan

Normality Study Interview Questionnaire Check Sheet Observation Process Chart Opportunity Flowchart Time Value Map Sequence Chart VSM Flowchart

BASELINE STUDY DATA COLLECTION DATA SYSTEM KEY PROCESS VARIABLES AS-IS PROCESS STUDY

Histogram Box Plot

ANALYZE

Run C&E Hypothesis

Brainstor-ming 5W1H
Matrix
FMEA Testing
ANOVA Correlation Regression
Chart

Probability Distribution Waste Analysis Value Analysis 5 Whys Why-Why Diagram Fishbone Diagram Pareto Analysis Relationship Mapping Scatter Diagram

PROCESS ANALYSIS CAUSES IDENTIFICATION ROOT CAUSE ANALYSIS CAUSES VERIFICATION MODELING
DOE

IMPROVE
Brainstor-
Capability Quick Kaizen Pilot
Study SPC MSA Events
SCAMPER ming
Wins Study
Normality Study Graphical Methods Flowchart PDCA Risk Analysis RACI Matrix Gantt Chart Paired Comparison Pugh Matrix Balanced Sheet Prioritization Matrix How-How Diagram

OUTCOME VS. BASELINE IMPLEMENTATION PLAN IMPLEMENTATION SOLUTION SELECTION SOLUTIONS GENERATION
CONTROL

Training
Control Mistake Skills Lessons Process
Plan Proofing
TPM Plan Storyboard
Learned
SPC Audit
Deployment Matrix

5S Standard Work SOP Visual Management Best Practice Sharing KPIs Project Closure

CONTROL MEASURES STANDARDIZATION HANDING OVER BENEFITS SHARING CONTINUOUS MONITORING

DEFINE
Kano Y=f(x) Risk Quick
VOC Analysis CTQ Cascade
COPQ PERT
Analysis Wins

Benchmarking Force Field Analysis Pareto Analysis Prioritization QFD KPIs SIPOC analysis VSM Stakeholder Analysis Project Charter Gantt Chart

BUSINESS CASE CUSTOMER NEEDS HIGH LEVEL PROCESS CHARTER PROJECT PLAN

Process Mapping

MEASURE
Process
Capability Normality Measles Check Operational Opportunity Spaghetti
SPC MSA Interview Sampling Definition Flowchart Diagram
Sequence
Study Study Chart Sheet Chart

Questionnaire Observation Data Collection Plan Process Chart Time Value Map VSM Flowchart

BASELINE STUDY DATA COLLECTION DATA SYSTEM KEY PROCESS VARIABLES AS-IS PROCESS STUDY

Histogram Box Plot

ANALYZE

Probability Run Waste Value Why-Why Relationship Hypothesis

Distribution
Brainstor-ming 5W1H ANOVA Correlation Regression
Chart Analysis Analysis Diagram Mapping Testing

5 Whys Fishbone Diagram C&E Matrix Pareto Analysis FMEA Scatter Diagram

PROCESS ANALYSIS CAUSES IDENTIFICATION ROOT CAUSE ANALYSIS CAUSES VERIFICATION MODELING
DOE

IMPROVE
Decision
Capability Normality Graphical Pilot Risk Paired How-How Brainstor-
Study SPC MSA Comparison
Balanced
Diagram
SCAMPER
Study Methods Study Analysis Sheet ming

Flowchart Kaizen Report Kaizen Event Charter PDCA RACI Matrix Gantt Chart Pugh Matrix Prioritization Matrix

OUTCOME VS. BASELINE IMPLEMENTATION PLAN IMPLEMENTATION SOLUTION SELECTION SOLUTIONS GENERATION
CONTROL

Training Best
Mistake Standard Lessons
TPM Plan Storyboard
Learned
Practice SPC
Proofing Work Deployment Sharing
Control Plan 5S SOP Visual Management Skills Matrix Audit Checklist KPIs Project Closure

CONTROL MEASURES STANDARDIZATION HANDING OVER BENEFITS SHARING CONTINUOUS MONITORING

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