In which phase of DMAIC solutions are identified and identified solutions are implemented?

Quality Glossary Definition: DMAIC

Define, measure, analyze, improve, and control (DMAIC) is a data-driven quality strategy used to improve processes. The letters in the acronym represent the five phases that make up the process, including the tools to use to complete those phases shown in Figure 1. It is an integral part of a Six Sigma initiative, but in general can be implemented as a standalone quality improvement procedure or as part of other process improvement initiatives such as lean. 

Figure 1: The DMAIC Methodology

The DMAIC Process

1. Define the problem, improvement activity, opportunity for improvement, the project goals, and customer (internal and external) requirements.
   • Project charter to define the focus, scope, direction, and motivation for the improvement team
   • Voice of the customer to understand feedback from current and future customers indicating offerings that satisfy, delight, and dissatisfy them
   • Value stream map to provide an overview of an entire process, starting and finishing at the customer, and analyzing what is required to meet customer needs
2. Measure process performance.
   • Process map for recording the activities performed as part of a process
   • Capability analysis to assess the ability of a process to meet specifications
   • Pareto chart to analyze the frequency of problems or causes
3. Analyze the process to determine root causes of variation and poor performance (defects).
   • Root cause analysis (RCA) to uncover causes
   • Failure mode and effects analysis (FMEA) for identifying possible product, service, and process failures
   • Multi-vari chart to detect different types of variation within a process
4. Improve process performance by addressing and eliminating the root causes.
   • Design of experiments (DOE) to solve problems from complex processes or systems where there are many factors influencing the outcome and where it is impossible to isolate one factor or variable from the others
   • Kaizen event to introduce rapid change by focusing on a narrow project and using the ideas and motivation of the people who do the work
5. Control the improved process and future process performance.
   • Quality control plan to document what is needed to keep an improved process at its current level
   • Statistical process control (SPC) for monitoring process behavior
   • 5S to create a workplace suited for visual control
   • Mistake proofing (poka-yoke) to make errors impossible or immediately detectable

DMAIC vs. DMADV

Define, Measure, Analyze, Design, and Verify (DMADV) is a data-driven quality strategy that focuses on the development of new products or services compared to existing ones. The DMADV method or approach is often used when implementing new strategies because of its basis in data, its ability to identify success early, and its method, which requires thorough analysis. Like DMAIC, it is an integral part of a Six Sigma quality initiative.

DMAIC resources

You can also search articles, case studies, and publications for DMAIC resources.

To DMAIC or Not To DMAIC? (Quality Progress) Identify when you need a structured method for problem solving.

DMAIC Failure Modes (Six Sigma Forum Magazine) Read about actual experiences related to some of the key failure modes associated with DMAIC and effective countermeasures you can take.

How to Scope DMAIC Projects (Quality Progress) Scoping is a vital part of the define phase and can have a long-term impact on a Six Sigma program’s ultimate success.

Excerpted from The Certified Quality Engineer Handbook, ASQ Quality Press.

SAGE Automation, Published: January 4, 2018 - Updated: August 26, 2018 (4 min read)

By now you should have clearly identified the process that needs improving, collected the data, and analysed it to come up with the root causes for the problem. Phase four of DMAIC: Improve, is where it gets fun.

Not up-to-date on Six Sigma? Read our Introduction to Six Sigma or start here for DMAIC Phase 1: Define.

About ‘Improve’

Improve is where you can finally begin to find solutions to the root causes of the problem.

It’s the most creative stage of DMAIC because it’s not heavily reliant on statistical analysis and instead asks people to come up with ideas for solutions. It’s also experimental, because each feasible idea will be tested on a pilot scale before being implemented.

Improve: Key steps

1. Invite people ‘back into the room’

Start brainstorming potential solutions to the problem at hand. It’s worth getting the operators or ‘everyday staff’ back into the room for this step. Present them with the problems you identified in Define, the root causes of those problems you identified in Measure and Analyse, and ask ‘How should we fix them?’. Facilitate a few sessions like this. Provide a deadline for ideas so staff can go away and think individually, on and off the job, and pass on ideas later.

2. Weigh up ideas and pilot the best ones

Select a small number of feasible solutions, then pilot them.

“Piloting is critical, because an idea that sounds wonderful in a room never quite turns out the same way on the shop floor,” University of South Australia’s Lean Six Sigma lecturer and consultant Dr Neil Davison explains.

Piloting saves time, money and frustration by eliminating failed ideas before they’re implemented on a large scale.

Here’s an example: you identify that variation in a cooking process can be attributed to the number of raw materials suppliers you have. You propose reducing the amount of suppliers to one or two for a limited time. You might find that the defect rates drop, but you have trouble getting enough consistent supply, because the higher-quality material is produced in lower volumes. So, although the idea looked good, the pilot proved it wasn’t viable.

3. Select the winning idea

By the end of the Improve phase, you should have ruled out multiple solutions through pilot programs and found at least one to implement on a large scale.

People involved in Improve

Improve is the most consultative phase of DMAIC. Involve people from different levels within the business, including those that work directly with the ‘problem process’. In manufacturing, operators and production staff should be engaged in idea generation and discussions with the project team.

Collaboration with those on the shop floor will ensure they have ownership over the solution, which is vital in making any changes stick long term. It will also mean you get the best improvement suggestions, right from the people who know the day-to-day realities of the work.

Summary

By the end of Improve, you’ll have tested a handful of ideas that were generated by staff within the organisation. You’ll have a proof-of-concept for one or maybe even a few solutions that were successful in pilot conditions. Stay tuned for the final and most important phase of DMAIC: Control. 

Innovative solutions and ideas set to improve our client’s wants and needs is how we work at SAGE. See how we’ve helped keep planes flying at Adelaide Airport through innovative problem solving. Learn more.

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In what phase of DMAIC is a solution or solutions identified that will maximize return on investment?

In which phase of DMAIC potential causes are identified and data collection is initiated?

What are the 5 phases included in a DMAIC?

Which items should be identified in the Define phase of DMAIC cycle?