SMRP BoK Review Workbook

DMAIC

In an effort to bring operations to a “six sigma” level – essentially 3.4 defects
for every one million opportunities – the methodology calls for continuous
efforts to get processes to the point where they produce stable and
predictable results.

Deconstructing the manufacturing process down to its essential parts, Six
Sigma defines and evaluates each step of a process, searching for ways to
improve efficiencies in a business structure, improve the quality of the process
and increase the bottom-line profit.

Toward that end, the methodology calls for the training of personnel in Six
Sigma, including beginner Green Belts, Black Belts who often head up
individual projects, and Master Black Belts who look for ways to apply Six
Sigma across a business structure to make improvements.

The ultimate goal is to improve every process to a “six sigma” level or better.
Does it work? Motorola reported in 2006 that the company had saved $17
billion using Six Sigma.

Ultimately, all of the tools and methodologies in Six Sigma serve one purpose:
to streamline business processes in order to produce the best products and
services possible with the smallest amount of defects. Its adoption by

corporations around the globe is both an indicator of and testament to its

remarkable success in today’s business environment.

It uses DMAIC: This method is used primarily for improving existing business

processes. The letters stand for:

Define: What problem would you like to fix? The Define Phase is the first

phase of the Lean Six Sigma improvement process. In this phase the project

team creates a Project Charter, a high-level map of the process and begins to

understand the needs of the customers of the process. This is a critical phase

in which the team outlines the project focus for themselves and the leadership

of the organization.

▪ Define the problem statement

▪ Define the goal

▪ Define the process (process mapping)

▪ Define the customer and their requirements

▪ Inform others of progress

Measure: How does the process currently perform? Or in other words, what

is the magnitude of the problem? Measurement is critical throughout the life

of the project. As the team starts collecting data they focus on both the

process as well as measuring what customers care about. That means initially

there are two focuses: reducing lead time or improving quality. In the Measure

Phase, the team refines the measurement definitions and determines the

current performance or the baseline of the process.

▪ Determine how the process currently performs

▪ Create a plan to collect data

▪ Ensure the data is reliable

▪ Gather baseline data

▪ Update project charter

Analyze: What is causing the problem? The Analyze Phase is often not given

enough attention and, without analysis, teams jump to solutions before

knowing the true root causes of the issues. The result is teams who implement

solutions but don’t resolve the problem! These efforts waste time, consume