How do you use Lean principles in DMAIC?

1 Define the problem

The first step in any improvement project is to clearly define the problem you want to solve, the scope of the project, the goals and objectives, and the customer requirements. Lean principles can help you to do this by using tools such as the voice of the customer (VOC), the value stream map (VSM), and the SIPOC diagram (suppliers, inputs, processes, outputs, customers). These tools can help you to identify the value-added and non-value-added activities in your process, the sources of waste and inefficiency, and the gaps between customer expectations and actual performance.

2 Measure the current state

The next step is to measure the current state of your process and collect data on the key performance indicators (KPIs) that are relevant to your problem and goals. Lean principles can help you to do this by using tools such as the 5S method (sort, set in order, shine, standardize, sustain), the gemba walk (going to the actual place where the work is done), and the spaghetti diagram (a visual representation of the flow of materials, information, and people in a process). These tools can help you to organize your work environment, observe the reality of your process, and identify the sources of variation and waste.

3 Analyze the root causes

The third step is to analyze the data you collected and identify the root causes of the problem. Lean principles can help you to do this by using tools such as the fishbone diagram (also known as the cause-and-effect diagram or the Ishikawa diagram), the 5 whys technique (asking why repeatedly until you reach the root cause), and the Pareto chart (a bar chart that shows the frequency or impact of different causes). These tools can help you to organize your data, drill down to the underlying factors, and prioritize the most significant causes.

4 Improve the process

The fourth step is to design and implement solutions that address the root causes and improve the process. Lean principles can help you to do this by using tools such as the kaizen event (a short-term, focused improvement activity), the poka-yoke (also known as mistake-proofing or error-proofing), and the kanban system (a visual system that controls the flow of work and inventory). These tools can help you to involve your team, prevent errors and defects, and optimize your process flow and capacity.

5 Control the results

The final step is to monitor and sustain the results of your improvement project and prevent backsliding. Lean principles can help you to do this by using tools such as the control chart (a graphical tool that tracks the performance of a process over time and detects any changes), the standard work (a documented and agreed-upon way of performing a task), and the PDCA cycle (plan, do, check, act, a continuous improvement cycle). These tools can help you to measure and evaluate your results, document and communicate your best practices, and identify and act on new opportunities for improvement.

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?