DMAIC Steps

Define Phase

Step 01 - Understand customer and business requirements; Step 02 - Complete the project charter; Step 03 - Complete high-level as is process map.

Measure Phase

Step 04 - Identify what to measure; Step 05 - Plan and collect data; Step 06 - Determine baseline performance.

Analyze Phase

Step 07 - Identify performance gaps; Step 08 - Ascertain critical root causes; Step 09 - Validate root causes.

Improve Phase

Step 10 - Generate, prioritize and select solution(s); Step 11 - Pilot solution(s); Step 12 - Validate impact of solution(s).

Control Phase

Step 13 - Institutionalize the solution(s); Step 14 - Replicate and share best practices; Step 15 - Celebrate and recognize success.

Step 01 - Understand customer and business requirements

In this step, you try to define the problem from the customer's perspective. Tools include -> Voice of Customer (VOC), Affinity Diagram, Translating Needs to Requirements, Kano Analysis, Critical to Quality (CTQ) Tree.

Step 02 - Complete the project charter

In this step, you answer the following questions. How do you know there is a problem. What specific measures indicate there is a problem. What will success look like. What is the scope. Who is on the team and what are their roles and responsibilities. What is your project plan. Tools include -> Project Charter, Change Acceleration Process (CAP) tools such as ARMI (Approver, Resource, Member and Interested Party), RACI (Responsible, Accountable, Consulted and Informed), Threat vs. Opportunity Matrix, Stakeholder Analysis, and Elevator Speech.

Step 03 - Complete high-level as is process map

In this step, you identify where the problem is occurring. Tools include -> SIPOC.

Step 04 - Identify what to measure

In this step, you answer the following questions. What does the detailed process currently look like. What is the output (Y) and primary measures (X's). What data can be used to measure how the process is currently performing. Tools include -> Cost of Poor Quality (COPQ), 8 Wastes, Process Map, Value Stream Map (VSM), and Takt Time.

Step 05 - Plan and collect data

In this step, you focus on creating a robust data collection plan and identify what is said by the data. Tools include -> XY Matrix, Data Collection Plan, Operational Definitions, Sampling, Measurement System Analysis.

Step 06 - Determine baseline performance

In this step, you identify if the process is stable and if it is capable of meeting customer requirements. Tools include -> Run Chart, Normality Test, Yield, Process Capability Analysis – Discrete Data, and Process Capability Analysis – Continuous Data.

Step 07 - Identify performance gaps

In this step, you try to understand the sources of variation and waste. You also do a root cause analysis and identify the potential causes of the problem. The root causes that you identify in this step are known as Trivial Many X's. Tools include -> Brainstorming, Fishbone Diagram, Five Whys.

Step 08 - Ascertain critical root causes

In this step, you use graphical tests and identify what insights do these graphs and data reveal on the root causes. You focus on getting a shortened list of critical root causes. These are called as Critical X's. Tools include -> Pareto Chart, Box Plot, Scatter Plot, Multi-voting, and Control-Impact Matrix.

Step 09 - Validate root causes

In this step, you confirm if the root causes have a significant impact on the problem. Our objective is to boil down to just 3 to 6 root causes of the identified list of trivial many root causes. These 3 to 6 root causes are called as vital few X's. Hypothesis Testing is the primary technique used. Statistical tests include -> 1-Sample t, 2-Sample t, Paired t, One-Way ANOVA, 1-Variance, 2-Variance, Test of Equal Variances, 1-Sample Sign, Mann Whitney, Moods Median, Correlation, Regression, Chi-Square, 1-Proportion, and 2-Proportion test.

Step 10 - Generate, prioritize and select solution(s)

In this step, you address the following questions. What will fix the root causes. How do the solutions address specific root causes identified. What solutions have been selected and why. What is the cost/benefit. Tools include -> Brainstorming, Benchmarking, Brainwriting, Assumption Busting, Analogy Technique, Channeling Technique, Anti-Solution Technique. Lean tools include -> 5S, Set Up Reduction, Heijunka, Generic Pull, Jidoka, Just In Time, and Solution Selection Matrix.

Step 11 - Pilot solution(s)

In this step, you determine how your identified solutions will be successful. Tools include -> Pilot Plan, Poka-Yoke, FMEA, and Implementation Planning.

Step 12 - Validate impact of solution(s)

In this step, you confirm if the problem is indeed fixed and you start tracking the on-going benefits arising out of the improved processes. Tools include -> Cost Benefit Analysis, Measurement System Re-Analysis, and Process Capability.

Step 13 - Institutionalize the solution(s)

In this step, you work towards answering the following questions. What is the plan to implement the solutions. Who is doing what. How will you track process performance. What action will be taken if the problem returns. Tools include -> Visual Management Boards (VMBs), Team Huddles, Control Plan, Standard Operating Procedures (SOPs), and Go Gemba. Control Charts include -> I-MR Chart, X bar R Chart, X bar S Chart, np Chart, p Chart, c Chart, and u Chart.

Step 14 - Replicate and share best practices

In this step, you further answer the following questions. How will you capture knowledge related to best practices and what makes them effective. How will you connect current practitioners and potential adopters of best practices. What support will you provide to adopters over time.

Step 15 - Celebrate and recognize success

In this step, you identify the ways and means to share the project results with larger audience. You also showcase and reward individual contributors.