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How can DMAIC be used to streamline your manufacturing process?

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If you want to improve your manufacturing process and eliminate waste, defects, and variation, you might want to try DMAIC. DMAIC stands for Define, Measure, Analyze, Improve, and Control, and it is a systematic approach to problem-solving and process improvement based on Lean Six Sigma principles. In this article, we will explain how you can use DMAIC to streamline your manufacturing process and achieve better results.

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Padma Kulkarni

Food Scientist | Quality Systems Leader | Global Industry Leader | Lean Six Sigma Green Belt, Food Safety, HACCP, PCQI…

1 Define the problem

The first step of DMAIC is to define the problem or the opportunity that you want to address. You need to clearly state the goal, scope, and timeline of your project, as well as the customer requirements and expectations. You also need to identify the key stakeholders and team members who will be involved in the project. A useful tool to help you define the problem is a project charter, which summarizes the main elements of your project in one document.

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Sakkie Coetzee

Process Development Specialists
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Understand the difference between what is wrong (cause), and what is the problem (symptom or result). Remember, you do not know what is wrong. That is why you are doing the DMAIC. The one is a symptom and/or result, the other a cause. At this stage you do not know the cause. Do not assume a cause. Example. A floor mat is full of hair. Problem statement: The cat is shedding hair on the mat.....WRONG, that is an assumption until proven. Correct problem Statement: There is hair on the floor mat. Before you have proven that the cat is shedding on the mat, you are assuming. This is important, or you could be missing that the hair is brought in by the wind.

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2 Measure the current state

The second step of DMAIC is to measure the current state of your process and collect relevant data. You need to define the metrics that will help you evaluate the performance and quality of your process, such as cycle time, defect rate, yield, customer satisfaction, etc. You also need to establish a baseline for your current process and validate the accuracy and reliability of your data. A useful tool to help you measure the current state is a process map, which shows the flow of activities, inputs, outputs, and resources in your process.

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Padma Kulkarni

Food Scientist | Quality Systems Leader | Global Industry Leader | Lean Six Sigma Green Belt, Food Safety, HACCP, PCQI | Led process improvement initiatives
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Once you have the problem defined, you have your action steps in place, you would have defined what needs to be measured. One can get started with the process map and ask the following questions: When is the problem? Where is the problem occurring? What is the baseline performance of this process? Just how bad is the current process? What is the gap between the current and target performance? How good is the measuring system?

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Sakkie Coetzee

Process Development Specialists
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Data reliability, or the lack there-of, is arguably the single biggest reason why improvement projects fail. Every step in DMAIC is important, but this one is super critical. Again, do not assume. Until you KNOW that data is accurate and reliable, do not trust or use it. If you get this step right, the rest will pretty much take care of itself. Take time, and make certain beyond any reasonable doubt.

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3 Analyze the root causes

The third step of DMAIC is to analyze the root causes of the problem or the gap between the current and the desired state. You need to use various statistical and analytical tools to identify the factors that influence your process and the sources of variation and waste. You also need to prioritize the most critical and significant causes that need to be addressed. A useful tool to help you analyze the root causes is a fishbone diagram, which illustrates the relationship between the problem and its potential causes.

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Padma Kulkarni

Food Scientist | Quality Systems Leader | Global Industry Leader | Lean Six Sigma Green Belt, Food Safety, HACCP, PCQI | Led process improvement initiatives
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In my experience, root cause analysis is a 3 step process: 1. Identify as many potential root causes as possible. 2. Screen and prioritize the root causes to a manageable number (e.g.: top 3 or top 5). 3. After prioritization, validate the root causes as inputs that could be the largest contributors to the problem and evaluate their impact on the output. These critical inputs (root causes) are the key issues that are addressed during the Improve phase. Some tools that can be used to identify root causes are: process map, pareto chart, fishbone, 5 whys, brainstorming, hypothesis testing, FMEA.

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4 Improve the process

The fourth step of DMAIC is to improve the process by implementing solutions that address the root causes. You need to generate and evaluate various ideas for improvement, such as eliminating non-value-added activities, reducing complexity, simplifying steps, standardizing procedures, etc. You also need to test and validate the effectiveness of your solutions using experiments, simulations, or pilot runs. A useful tool to help you improve the process is a PDSA cycle, which stands for Plan, Do, Study, Act, and it is a method for testing and learning from changes.

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5 Control the process

The fifth and final step of DMAIC is to control the process by ensuring that the improvements are sustained and monitored. You need to document and communicate the changes made to the process and train the staff on the new procedures. You also need to establish control charts, dashboards, or other tools to track the performance and quality of the process and detect any deviations or issues. A useful tool to help you control the process is a control plan, which specifies the roles, responsibilities, and actions required to maintain the process.

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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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How can DMAIC be used to streamline your manufacturing process?

1

2

3

4

5

6

1 Define the problem

2 Measure the current state

3 Analyze the root causes

4 Improve the process

5 Control the process

6 Here’s what else to consider

Lean Manufacturing

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How can DMAIC be used to streamline your manufacturing process?

1

2

3

4

5

6

1 Define the problem

2 Measure the current state

3 Analyze the root causes

4 Improve the process

5 Control the process

6 Here’s what else to consider

Lean Manufacturing

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