DMAIC Method

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  The DMAIC Method is a problem solving methodology used within a six sigma strategy.  The methodology focuses on improving business processes, specifically through the improvement of quality and reducing variation.  It is an Integral part of six sigma.

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  Almost all of the six sigma projects you engage in for processes that are already established will use the DMAIC method.  The acronym represents each of the 5 stages of the methodology:

1. Define.
2. Measure.
3. Analyze.
4. Improve.
5. Control.

As with any formal problem solving methodology, the structured approach creates a common understanding and language that promotes effectiveness and efficiency amongst team members.  Especially when applied to projects.

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Define:

• In the first stage of the DMAIC method potential projects are identified, evaluated and ultimately selected.  A problem statement is normally drafted along with goals so that everyone understands what needs to be done.  Essentially, this critical first stage sets the context and scope within which the project is to be executed.

Measure:

• After everything has been defined, we move on to the measure stage.  In this stage you begin to collect the appropriate metrics so that you can understand the current state or baseline and any associated constraints with the process you are working on.  This is typically done using: process maps, value stream mapping, gemba walkthrough, videotaping, brainstorming, fishbone diagrams or any other tool that will allow you to reveal the current state.

Analyze:

• The third stage reviews the collected metrics and analyzes all pieces of information that has been collected.  A variety of tools can be used to diagnose and present a root cause/causes.  Some tools that will help you understand the various issues you will find in this stage are:
  • Fishbone diagrams.
  • Five whys.
  • Control charts.
  • Process maps.
  • Check sheets.
  • Pareto charts.
  • Scatter diagrams.

  Each of these tools will help you reveal different levels of causation so that you can look to remove the actual cause of the problem and not just the symptoms that occur as a result of the root cause.
Improve:

• As you can see each of the stages in the DMAIC method build on one another.  Each stage, in a sense, is dependent on the previous stage and can not move forward without the previous stages completion and accuracy.  Now that we have metrics and analysis available to look at we can define each of the problem solving formula variables.  Remember, Y= f(x) + ϵ.  Once these variables are defined the Gap between our current state and goal will be much easier to understand and we can begin looking at potential countermeasures, refinements, alternative remedies or improvements for the process that we are looking at.  As you identify where and how variances are occurring in the process (function) you will be able to determine how you can improve the process (function) with solutions that will help you achieve your original goal or solve the initial problem that you defined in a problem statement.  After you have a few different solutions that you would like to try out you can then implement the new process or system within a controlled environment and take some time to monitor and measure the results.  This will help you ensure that the process you are about to release is in fact an improved process that can sustain the results that you observe.  Some methods that you can use to test your possible improvements:
  • Production experiments.
  • Simulations.
  • Trial runs.
  • Dominant variable testing.

Control:

• In this final control stage various design controls are established and the improved process is documented.  A system of measurement for the process is validated to plan for future improvements and ensure the process is performing to the best of its ability.  Another critical part of this control phase is the transfer or release of responsibility from the six sigma project team back to the business or appropriate department.  Once the process has been transferred back to the appropriate process owner the six sigma team will still coordinate with the process owner to ensure sustainability of the project.  Many times in the control phase methods such as poka yoke, 5S, statistical process control, regular audits or a process control plan are used to maintain or sustain the improvements that have been implemented.

 
  As you can see the DMAIC method is a very structured process.  Each of the 5 stages allows a team to guide a problem in the direction of a solution and close gaps within an organization.  Keep in mind that each phase of the process will require different individuals and skills to be used.  For example, in the define stage collaboration with management and the appointed project lead (black belt) is crucial in clearly defining a workable problem statement and an achievable goal.  In the later stages of the DMAIC methodology (measure, analyze and improve) the project team will do the vast majority of the leg work while green and black belts use their experience and skill set to gather needed information. 

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