Supercharging DMAIC
IT’S TIME TO USE THE POWER OF THE
COLLECTIVE MIND
Traditional Lean Sigma Toolkit and Methodology-DMAIC
2
Phases
Reviews (tollgate meetings)
1.0
1.0
Define
Define Opportunities
Opportunities
1. Complete Project Charter
2.0
Measure
Performance
4. Identify what to measure
Tools:
 Charter:
- Business case
- Opportunity Statement/ Goal
Statement
 Project Scope
 Project Team, Project Plan
 Preliminary Problem
Statement
Tools:
 FMEA
 C&E Matrix
 Data Collection Plan
 Functional Process Map
 VA/ NVA Analysis
 Value Stream Mapping
 TAKT Analysis
2. Specify customer and
business requirements
Tools:
 VOC/ VOB
 Stakeholder Analysis
 CTQ Tree
 Kano Model
 Change Management
 Elevator Speech
3. Complete high level SIPOC
5. Plan and collect data
Tools:
 Block Diagram
 5S
 SIPOC
Quick Wins / *RIP/
Kaizen
Define Tollgate Sign-Off:
Contract between the sponsor
and team as to what they are
going to work on
3.0
Analyze Root
Causes
7. Refine problem statement
Tools:
 Fishbone Diagram
 Brainstorming
 Five Whys
 Value Stream Analysis
4.0
Improve
10. Generate, prioritize and
select solution ideas
Tools:
 Brainstorming
 5S
 Poka Yoke
 Rapid Setup
 Pull Systems
5.0
Control
Performance
13. Institutionalize
the solution
Tools:
 Change Management
 Stakeholder Analysis
 Process Capability
 Process Control Plan &
dashboard
 Signed off benefits
 Control Charts
14. Replicate and share best
practices
Tools:
 Project Database
 Lean Sigma Network
8. Rank key causes of
variation
Tools:
 Descriptive Statistics
 Stratification
 Graphical Analysis
 Value Stream Analysis
 FMEA
11. Validate impact of
solution(s)
Tools:
 Should be process map
 Cost/ Benefit Analysis
 Multi-voting
 Solution selection matrix
 FMEA
6. Determine process
baseline capability
9. Validate root causes
12. Develop full scale
implementation report
15. Celebrate
Tools:
 Process Capability
 Pareto
 Descriptive Statistics
 Control Chart
Tools:
 Graphical Analysis
 Pareto
Tools:
 Project Plan
 Pilot
 Solution implementation
report
 FMEA
Tools:
 Project Database
 Lean Sigma Network
 Celebrate
Engineer Tollgate Sign-Off:
Proposed solutions validated
and implemented
Control Tollgate Sign-Off:
Solutions institutionalized
and offered for replication
Tools:
 Data Collection Plan
 Operational definitions
 Measurement System
Analysis
 Sample Size
Quick Wins / RIP?
Quick Wins / RIP?
3
Supercharged DMAIC
Phases
Reviews (tollgate meetings)
1.01.0
Define
Define Opportunities
Opportunities
1. Complete Project Charter
2.0
Measure
Performance
4. Identify what to measure
3.0
Analyze Root
Causes
4.0
Improve &
Innovate
7. Refine problem
statement10. Generate, prioritize
and select solution ideas
Tools:
 Charter:
- Business case
- Opportunity Statement/ Goal
Statement
 Project Scope
 Project Team, Project Plan
 Preliminary Problem
Statement
Tools:
 FMEA
 C&E Matrix
 Data Collection Plan
 Functional Process Map
 VA/ NVA Analysis
 Value Stream Mapping
 TAKT Analysis
2. Specify customer and
business requirements
Tools:
 VOC/ VOB
 Stakeholder Analysis
 CTQ Tree
 Kano Model
 Change Management
 Elevator Speech
3. Complete high level
SIPOC and clean up
Tools:
 Block Diagram
 5S
 SIPOC
5. Plan and collect data
8. Rank key causes of
waste and variation
Tools:
 Data Collection Plan
 Operational definitions
 Measurement System
Analysis
 Sample Size Calculator
Tools:
 Descriptive Statistics
 Stratification
 Graphical Analysis
 Value Stream Analysis
 FMEA
6. Determine process
baseline capability
9. Validate root causes
Tools:
 Process Capability
 Pareto
 Descriptive Statistics
 Control Charts
Tools:
 Graphical Analysis
 Pareto
Quick Wins *RIP/
Kaizen?
Define Tollgate Sign-Off:
Contract between the sponsor
and team agreeing on project
scope and goals.
Quick Wins / RIP?
Tools:
 Fishbone Diagram
 Brainstorming
 Five Whys
 Value Stream Analysis
Quick Wins / RIP?
Tools:
 Brainstorming
 5S
 Poka Yoke
 Rapid Setup
 Pull Systems
11. Validate impact of
solution(s)
Tools:
 Should be process map
 Cost/ Benefit Analysis
 Multi-voting
 Solution selection matrix
 FMEA
12. Develop full scale
implementation plan and
execute
Tools:
 Project Plan
 Pilot
 Solution implementation
report
 FMEA
Engineer Tollgate Sign-Off:
Proposed solutions validated
and implemented
5.0
Control
Performance
13. Institutionalize
the solution
Tools:
 Change Management
 Stakeholder Analysis
 Process Capability
 Process Control Plan &
dashboard
 Signed off benefits
 Control Charts
14. Replicate and share
best practices
Tools:
 Project Database
Knowledge management
process
 Lean Sigma Network
15. Celebrate!
Tools:
 Project Database
 Lean Sigma Network
 Appropriate Cultural
Rewards and, or
Recognition
Control Tollgate Sign-Off:
Solutions institutionalized
and offered for replication