QMS - DMAIC Process

DMAIC

A structured, five-step problem-solving procedure used to solve root causes of quality and process problems.

Goal of DMAIC

To solve root causes of quality and process problems and establish best practices for long-lasting and replicable solutions.

Symptoms

Visible outcomes of a problem that indicate an underlying issue.

The Problem

The gap between the current performance and the desired goal or standard.

Root Causes

Underlying issues that are not immediately obvious and contribute to the problem.

DMAIC

A methodology associated with Six Sigma, applicable in lean projects to identify opportunities, analyze data, develop solutions, and manage improvement.

Tollgates

Checkpoints for project teams to present findings to stakeholders during the DMAIC process.

Six Sigma Organizational Structure

Includes roles such as Leadership Team, Project Champion, Black Belts, Green Belts, and Master Black Belt.

Key Tools in DMAIC

Project charter, process maps, cause-and-effect analysis, hypothesis tests, and control plans.

Project Characteristics in Six Sigma

Must drive significant improvements and align with corporate goals, often targeting current problems.

Define

Identify valuable project opportunities and ensure alignment with customer needs, resulting in a project charter.

SIPOC Diagram

A visual mapping tool that outlines Suppliers, Inputs, Process, Outputs, and Customers.

Measure

Establish current baseline performance through data collection, focusing on KPIVs and KPOVs.

Data Collection Strategies

Utilize historical data and observational studies to gather relevant information.

Analyze

Determine cause-and-effect relationships and sources of variability, distinguishing between common and special causes.

Key Tools in Analyze Step

Control charts, statistical hypothesis testing, regression analysis, and FMEA (Failure Mode and Effects Analysis).

Improve

Develop and implement solutions to address identified root causes through process redesign and mistake-proofing.

Control

Ensure that improvements are sustained over time by developing a control plan and scheduling follow-up validations.

Key Process Input Variables

Critical inputs that directly impact the process’e performance and outcomes

Key Process Output Variables

Measurable results that reflect the process’s effectiveness

Common causes

Inherent variability within the process stemming from design or operation; these are systemic in nature and difficult to isolate

Specific Causes

Identifiable factors or events disrupting normal process flow; traceable to particular issues or external conditions

Poka-Yoke

The other term for mistake proofing in the improve step of the DMAIC process