The DMAIC Process: The Core of Six Sigma Methodology

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As new technologies rapidly emerge in various industries, competition rapidly increases as companies become nothing short of determined to achieve competitive advantage and legitimacy when producing quality products. Also, this rise in competition has pushed firms to embrace data to drive operational efficiency. One such quality system that has gained traction is the DMAIC method.

DMAIC is an improvement tool that addresses the process and service problems. It is the basis of Lean Six Sigma. Many companies use Six Sigma to rectify errors and enhance operations. Six Sigma also focuses on eliminating waste of resources, time, and effort to produce value. Additionally by applying the DMAIC methodology has delivered “value” through cost reduction, improved quality, and increased revenues, amongst other benefits.

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The DMAIC Process

DMAIC is short for Define, Measure, Analyze, and Control. Each term represents a phase of the DMAIC methodology, which serves a specific purpose. The phases are meant to guide the teams through identifying a problem, determining the baseline, identifying the root cause, resolving the issue, and implementing the solution.

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The roots of the DMAIC methodology can be traced back to the 1930s when Walter Shewhart and W. Edward Demming developed the Plan-DO-Study-Act (PDSA) cycle. But the DMAIC methodology, the cornerstone of the Six Sigma process, was designed by Bill Smith and Harry Mikal, in the 1980s. At that time Motorola was trying to intensify its quality initiative to catch up with Japanese competitors. As you can see the process has been yielding results for ages.

When Should The DMAIC Process Be Used?

In some cases, we can make improvements without a complete DMAIC. For example, in cases where the root cause is clear and corrective change is evident, we can directly make the change without the DMAIC process. But in the cases which have numerous functional areas involved, and previous improvements have failed, we need to follow the DMAIC process.

In short DMAIC process can be applied when:

The existing process needs improvement.
The root cause of the poor performance is unclear.
When you can reduce variables while improving the process.
The process has complex problems.

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The Phases And Steps Of The DMAIC Process

1. Define Phase

In this phase, we quite literally define the problem that needs to be solved. We also understand the weight the problem has for the organization and organize the improvement team.

Key Steps in the Define Phase include:

Creating a project charter that outlines the scope, objective, timeline, and resources required.
Defining specific measurable goals that align with the objective.
Developing the Voice of the Customer table (VOCT) to analyze feedback from current and future customers.
Creating a Value Stream map (VSM) to provide an overview of the entire process and analyze what is required to meet the customer needs.

A well-defined problem and clear objective prevent any deviation from the scope. Additionally, by setting a specific goal the project will have clear direction and measurable criteria.

2. Measure Phase

The Measure phase is where we draw a baseline to assess the performance of a given process. These baselines also help in drawing comparisons and track improvement.

Key steps in the Measure phase also include:

Developing a process map for recording the activities performed.
Developing data collection methods and recognizing input, processes, and output indicators.
Implementing capability analysis to gauge the ability of the process to meet the specifications.
Creating a Pareto Chart to analyze the frequency of the problems or causes.
Examining the current data.

Accurate data collection is important to understand the process and identify areas of improvement. Additionally, it also avoids assumption and guesswork and provides an objective basis for analysis.

3. Analyze Phase

The goal of this phase is to identify and test the underlying cause of the problem. This also makes sure that the improvement takes place from deep down.

Key steps in the Analyze Phase include:

A detailed root cause analysis (RCA) to determine the cause of the problem. This involves using techniques like change analysis, events and causal factor analysis, and so on.
Carrying out a failure mode and effect analysis (FMEA) to identify the possible process failure.
Creating a multi-vari chart to get a visual representation.

Any improvement efforts made without thorough analysis will not give the desired results. Hence identifying and validating the root cause ensures that we are targeting the root cause of the problem.

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4. Improve Phase

In this phase, the focus is on developing and implementing the solutions to address the root cause identified in the analysis phase. Also, this is where the changes are made to optimize the process.

Key steps in the Improve Phase also include:

Brainstorming to find a possible solution using creative problem-solving techniques.
- Design of experiments (DOE) to assess the expected benefit of the solution.
Testing of the solution on a small scale to assess its effectiveness.
Revise the plans and process maps according to the data collected in the previous stage.
Kaizen event to introduce rapid change by focusing on narrow projects. Informing the stakeholders about the new procedures.
Recording the changes made and updating the documentation to reflect the new procedure.

Implementing the solution is an important part of the DMAIC process. Hence using improvement management software will make this process easier.

5. Control Phase

The control phase involves monitoring the process to prevent regression and implementing the controls to maintain the gains. However, after changes are in place the process must be kept in check to ensure its long-term effectiveness.

Additionally the key steps in the Control Phase include:

Drafting a control plan to document what is needed to keep the improved process at its current level.
Mistake proofing to make errors impossible or detectable.
Statistical process control (SPC) for monitoring the behavior of the process
Using 5s to create a workplace suited for visual control and streamlining improvements.

In the Control phase, you can record the improvements in quantifiable terms like quality improvement, productivity increase, and customer satisfaction.

This phase continues until a new improvement requirement arises, at which point we must start the DMAIC Six Sigma Process again. Starting the process again can feel tedious, but once the team gets the hang of it, they will become comfortable with the approach.

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Conclusion

A common challenge in process improvement is that stakeholders often have varying perspectives on what defines optimal performance. Hence getting stakeholders aligned to achieve one goal is very important to fix any issues. This is what the DMAIC process helps you achieve. It also gives a structured approach that helps in identifying the root cause carrying out a change in process to make it efficient.

FAQs

1. Who uses the DMAIC process?

Ans: The Organizations that practice Six Sigma use the DMAIC Six Sigma process.

2. What is the most difficult phase in the DMAIC process?

Ans: Many professionals find the Analyze phase to be the most challenging, although this can vary depending on the project.

3. When is the DMAIC methodology not applicable?

Ans: If the root cause and solution are obvious then we can make the change in the process without going through the DMAIC process.

4. Is DMAIC a lean tool?

Ans: The DMAIC is not a lean tool, but many lean methodologies use it.

5. How long should a DMAIC project take to complete?

Ans: The DMAIC project can take 12 months or complete in just a few days. This depends on the project.

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