Six Sigma is a business management strategy used by many SMBs to identify errors and improve processes. Six Sigma-trained professionals use different tools and quality methods, such as the DMAIC method, which is a problem-solving roadmap that gives them a structured way to resolve issues.
In Six Sigma, there is no in-between and quality standards are either met, or they aren’t. Business owners must understand what their customers want and what variation is acceptable to them. Effective business systems and processes reduce any defects and delays to keep customers satisfied and reduce costs. DMAIC stands for define, measure, analyze, improve and control.
Define
Defining the specific problem is essential in order to successfully measure and solve it. The definition describes the problem numerically. For example, “damages to products in the production line have increased by 12% over the past six months”.
Just saying that the quality of products is not as good as it used to be is not enough. Part of this stage also involves defining the scope of the issue, all the business processes involved and the target goal. The team outlines the project focus for themselves and the leadership of the business.
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Measure
Measurements are necessary to quantify the problem. For example, looking at increases in damages to products requires looking at what specific products are involved, when the damage occurs, the level of damage etc.
Pareto analysis can identify the most occurring defects and prioritize the most critical problem to tackle. This allows the improvement team to have a more operational definition of the current state of the manufacturing process and the objective in terms of process improvement. The data collected can be used as a baseline to compare against measurements taken after project completion to see how successful it was.
Analyze
Once all the data is collected, analysis can begin. Teams often don’t give enough attention to the analysis phase and try to find solutions without identifying the root causes of the problem.
Analysis is necessary to identify ways to reduce the gap between current performance and the required objectives. This involves digging deeper into the data in order to develop hypotheses as to why damages to products occur. Is it an ongoing issue or is it more of a sporadic event?
The approaches and techniques normally used in the analysis stage include process mapping, brainstorming, cause-and-effect diagrams, hypothesis testing, statistical process control charts and simulation. The nature of the project and the way in which it’s conducted will normally dictate which approaches will be most effective.
Improve
This stage involves developing possible solutions for the root causes of the problem. Piloting these solutions can determine which of the solutions works best by collecting data to confirm measurable improvements.
The results of pilot studies may indicate by what percentage a particular solution improves the manufacturing process and reduces the amount of damage. Does the solution meet the target goal and, ultimately, improve the customer experience?
Control
Once the solution is tested and found to be effective, it is necessary to document it, update processes, and train all employees accordingly. It is also essential to design controls to monitor the processes and ensure that the fix is sustainable.
Control measurements may be taken on a daily, monthly or yearly basis. The team also crafts a response plan in case there is a dip in performance. The goal is to maintain the gains and continue to pursue perfection.