Lean Six Sigma is a continuous improvement methodology that focuses on the

elimination of waste and reduction of variation from manufacturing, service and

design processes. The Lean methodology aims at reducing non-value activities and
cycle times while creating value for customers. Six Sigma identifies and reduces
variability, improving overall quality. LSS can reduce your costs and help you retain
and even gain more customers.

DMAIC (Define—Measure—Analyze—Improve—Control)

DMAIC is the more well-known and most-used LSS project method. DMAIC focuses
on improving an existing process by incorporating the following phases:

DMAIC is a data-driven quality strategy used to improve processes. The letters in

the acronym represent the five phases that make up the process. It is an integral
part of a Six Sigma initiative, but in general can be implemented as a standalone
quality improvement procedure or as part of other process improvement initiatives
such as lean.

Phase Description

Define : Define the problem, output to be improved, customers, and process

associated with the problem.

Measure: Collect data from the process to establish a baseline for the
improvements.

Analyze: Analyze the data to find the root causes of defects.

Improve: Develop, test, and implement solutions to improve the process.

Control: Implement process controls to sustain the improvements.

THE DMAIC PROCESS

Define the problem, improvement activity, opportunity for improvement, the

project goals, and customer (internal and external) requirements.

Project charter to define the focus, scope, direction, and motivation for the
improvement team

Voice of the customer to understand feedback from current and future customers
indicating offerings that satisfy, delight, and dissatisfy them

Value stream map to provide an overview of an entire process, starting and

finishing at the customer, and analyzing what is required to meet customer needs

Measure process performance.

Process map for recording the activities performed as part of a process

Capability analysis to assess the ability of a process to meet specifications

Pareto chart to analyze the frequency of problems or causes

Analyze the process to determine root causes of variation and poor performance
(defects).

Root cause analysis (RCA) to uncover causes

Failure mode and effects analysis (FMEA) for identifying possible product, service,
and process failures

Multi-vari chart to detect different types of variation within a process

Improve process performance by addressing and eliminating the root causes.

Design of experiments (DOE) to solve problems from complex processes or systems

where there are many factors influencing the outcome and where it is impossible to
isolate one factor or variable from the others

Kaizen event to introduce rapid change by focusing on a narrow project and using
the ideas and motivation of the people who do the work

Control the improved process and future process performance.

Quality control plan to document what is needed to keep an improved process at its
current level

Statistical process control (SPC) for monitoring process behavior

5S to create a workplace suited for visual control

Mistake proofing (poka-yoke) to make errors impossible or immediately detectable

 DMADV (Define—Measure—Analyze—Design—Verify)

DMADV is focused on the process of designing a new product, service or process,

incorporating the following phases:

DMADV is a Six Sigma framework that focuses primarily on the development of a

new service, product or process as opposed to improving a previously existing one.
This approach – Define, Measure, Analyze, Design, Verify – is especially useful
when implementing new strategies and initiatives because of its basis in data, early
identification of success and thorough analysis.

The DMADV methodology should be applied:

when a non-existent product or process needs to be developed at a company and…

when an existing process or product already exists but still needs to meet a Six
Sigma level or customer specification.

Let’s examine the five major phases of DMADV more closely.

Define

The goals of the first phase are to identify the purpose of the project, process or
service, to identify and then set realistic and measurable goals as seen from the
perspectives of the organization and the stakeholder(s), to create the schedule and
guidelines for the review and to identify and assess potential risks. A clear definition
of the project is established during this step, and every strategy and goal must be
aligned with the expectations of the company and the customers.

Measurement

Next comes measuring the factors that are critical to quality, or CTQs. Steps taken
should include: defining requirements and market segments, identifying the critical
design parameters, designing scorecards that will evaluate the design components
more important to the quality, reassessing risk and assessing the production
process capability and product capability. Once the values for these factors are
known, then an effective approach can be taken to start the production process. It
is important here to determine which metrics are critical to the stakeholder and to
translate the customer requirements into clear project goals.

Analysis

Actions taken during this phase will include: developing design alternatives,
identifying the optimal combination of requirements to achieve value within
constraints, developing conceptual designs, evaluating then selecting the best
components, then developing the best possible design. It is during this stage that
an estimate of the total life cycle cost of the design is determined. After thoroughly
exploring the different design alternatives, what is the best design option available
for meeting the goals?

Design

This stage of DMADV includes both a detailed and high level design for the selected
alternative. The elements of the design are prioritized and from there a high level
design is developed. Once this step is complete, a more detailed model will be
prototyped in order to identify where errors may occur and to make necessary
modifications.

Verify
In the final phase, the team validates that the design is acceptable to all
stakeholders. Will the design be effective in the real world? Several pilot and
production runs will be necessary to ensure that the quality is the highest possible.
Here, expectations will be confirmed, deployment will be expanded and all lessons
learned will be documented. The Verify step also includes a plan to transition the
product or service to a routine operation and to ensure that this change is
sustainable.

For any DMADV project, there may be more emphasis on certain components of the
approach over others, though the goal remains the same: to address an identified
issue and produce desired results in a way that can be maintained through normal
operations.
DMADVO is a lesser known DFSS method. The difference between DMADV and
DMADVO is that “O” or “Optimize” has been added. Thus, DMADVO prioritizes the
need for the organization to optimize the design after implementation.

DMAIC vs DMADV

LSS prescribes an improvement process known as DMAIC (Define—Measure—

Analyze—Improve—Control). However, its application is limited to improving
existing processes. It doesn’t address the design of new products, services, or
processes.

For developing a new product, service or process, there’s a modified version called
DFSS (Design for Six Sigma). The process most often used in DFSS is called
DMADV (Define—Measure—Analyze—Design—Verify).

Similarities of DMAIC and DMADV

• Use structured methods to reduce variation and solve problems

• Collect and analyze data to make informed decisions
• Use teams to solve problems
• Have a customer focus
 • Use many of the same tools (brainstorming, FMEA, DOE)

Differences of DMAIC and DMADV

• DMAIC addresses the current process; DMADV addresses the design process.
• DMAIC reduces/eliminates defects (reactive); DMADV prevents defects
(proactive).
• DMAIC includes specific solutions; DMADV is part of the solution design
process.
• DMAIC includes controls to sustain the gains; DMADV includes verification
and validation of the finished design.

DMAIC and DMADV provide a structured process for improvement. When applied
properly with the applicable improvement tools, they can help ensure the success of
your LSS projects, which can reduce costs and increase customer satisfaction.