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How do you report Lean Six Sigma project results with DMAIC?

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Lean Six Sigma is a methodology that combines the principles of lean manufacturing and Six Sigma to improve processes, eliminate waste, and reduce variation. A key component of Lean Six Sigma is the DMAIC framework, which stands for Define, Measure, Analyze, Improve, and Control. DMAIC is a structured and data-driven approach to solving problems and implementing solutions. But how do you report the results of your Lean Six Sigma project using DMAIC? In this article, we will discuss some tips and best practices to communicate your project outcomes effectively and efficiently.

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1 Define the problem and goal

The first step of DMAIC is to define the problem and the goal of your project. This is where you establish the scope, objectives, stakeholders, and deliverables of your project. You should also identify the customer requirements, the current state of the process, and the gap between them. To report this step, you should use a clear and concise problem statement that describes the issue, its impact, and the desired outcome. You should also use a project charter that summarizes the project scope, team, timeline, resources, and risks.

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Emmy A. Emmanuel (PMP?, CSM?, M.Tech)

Project Management Professional | Process Optimisation Specialist | Risk Assessment & Management | Safety & Strategic Planning
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In Lean Six Sigma, defining a problem involves clearly stating its nature, impact, and the process involved. It should be measurable and specific, with well-defined boundaries to prevent scope creep. Setting a goal follows a similar approach, where the objective should be specific, measurable, achievable, relevant, and time-bound (SMART). This ensures that improvement efforts are focused and directed towards achieving a tangible outcome. For example, if the issue is excessive downtime in a manufacturing process, the goal could be to reduce it by 30% within the next six months, providing a clear direction for improvement initiatives.

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2 Measure the process performance

The second step of DMAIC is to measure the process performance and collect data to quantify the problem. This is where you define the critical input and output variables, the process metrics, and the data collection plan. You should also validate the measurement system and ensure its accuracy and reliability. To report this step, you should use graphical and statistical tools to display the baseline data and the process capability. You should also use a SIPOC diagram to show the high-level view of the process, its suppliers, inputs, outputs, and customers.

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3 Analyze the root causes

The third step of DMAIC is to analyze the root causes of the problem and identify the factors that influence the process performance. This is where you use various analytical techniques to test hypotheses, find correlations, and determine significance. You should also use tools such as fishbone diagrams, Pareto charts, and scatter plots to prioritize and visualize the root causes. To report this step, you should use a clear and logical reasoning to explain how you arrived at the root causes and how they affect the process output. You should also use evidence and data to support your analysis and conclusions.

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4 Improve the process

The fourth step of DMAIC is to improve the process by generating, selecting, and implementing solutions that address the root causes. This is where you use creativity and innovation to brainstorm potential ideas, evaluate their feasibility and impact, and plan their execution. You should also use tools such as pilot tests, design of experiments, and cost-benefit analysis to validate and optimize the solutions. To report this step, you should use a compelling and persuasive presentation to showcase the benefits and results of your solutions. You should also use charts and graphs to compare the before and after data and the process improvement.

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Jonobbas Baskaran

Operations Specialist | Lean Six Sigma-BB | Project Management | Manufacturing | Patents | 16+ years of experience in embracing continuous improvement and transformational leadership to create a sustainable future.
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This is important stage of the framework where real and required soulution for improvement is identified and implimented. The stakeholders will be waiting for this and will be ready to provide their positive and negative reviews on the improvements made. So the feedbacks and testimonials from the stakeholders, in specific from the customer may be a significant way of recording the improvement. It will add waitage for enacting more such projects in future.

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5 Control the process

The fifth and final step of DMAIC is to control the process by monitoring, sustaining, and standardizing the improvements. This is where you use tools such as control charts, control plans, and documentation to ensure the process performance remains stable and consistent. You should also use tools such as audits, reviews, and feedback to evaluate the customer satisfaction and the project success. To report this step, you should use a concise and factual summary to highlight the key achievements and outcomes of your project. You should also use a lessons learned report to share the best practices, challenges, and recommendations for future projects.

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Jonobbas Baskaran

Operations Specialist | Lean Six Sigma-BB | Project Management | Manufacturing | Patents | 16+ years of experience in embracing continuous improvement and transformational leadership to create a sustainable future.
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Mordern AI can be used to prepare live charts and even a comparison chart to compare with the previous state, before the implimentation of lean six sigma.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Jonobbas Baskaran

Operations Specialist | Lean Six Sigma-BB | Project Management | Manufacturing | Patents | 16+ years of experience in embracing continuous improvement and transformational leadership to create a sustainable future.
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We embarked on a Lean Six Sigma project to improve the manufacturing process of boiler headers, which normally took around 24 months. Surprisingly, we discovered that the main cause of delay was in the purchase stage, which wasn't discussed much in our meetings. Previously, the blame was often placed on the manufacturing division, but the DMAIC analysis revealed that the real issue was with the underutilization of the drilling facility, which we mistakenly thought needed more resources. It was a valuable and eye-opening experience for all of us.

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How do you report Lean Six Sigma project results with DMAIC?

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1 Define the problem and goal

2 Measure the process performance

3 Analyze the root causes

4 Improve the process

5 Control the process

6 Here’s what else to consider

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