ALL
DMAIC
TOOLS
6SGMA
BY: SUBHRANSU MOHANTY
Define Phase
Identify the problem and goals
Key Tools Description Examples
Example: A survey
Captures and
- Voice of the capturing customer
prioritizes customer
Customer (VOC) preferences for faster
needs and expectations.
delivery times in an
Provides a high-level
Example: Creating a
overview of the process
SIPOC diagram for the
by listing Suppliers,
- SIPOC Diagram order fulfillment
Inputs,
process in a
Process,Outputs, and
manufacturing plant.
Customers.
Example: A
Identifies stakeholders stakeholder analysis for
and their interests, a project aimed at
- Stakeholder Analysis
ensuring alignment increasing employee
throughout the project. satisfaction within an
organization.
Example: CTQ tree for
Breaks down
a restaurant focusing on
- CTQ Tree (Critical to customer needs into
food quality, speed of
Quality) measurable
service, and
components.
cleanliness.
Overview of the major Example: High-level
- High-Level Process steps in the process to process map of the
Map understand interactions hiring process in an HR
and boundaries. department.
Prioritizes customer Example: Applying the
needs based on Kano Model to identify
- Kano Model
satisfaction and the must-have features
performance impact. for a mobile phone.
Example: Risk
Identifies potential assessment for a new
- Risk Assessment risks, their impact, and product launch,
Matrix probability to address identifying potential
early-stage risks. supply chain
disruptions.
Measure Phase
Collect and analyze data
Key Tools Description Examples
Example: A flowchart to map
Process Mapping Detailed visual representation of
out the customer service process
(Flowchart) the process flow and interactions.
for handling complaints.
Specifies what data to collect, Example: A data collection plan
Data Collection
how, and from whom to ensure for tracking production defects in
Plan
relevant data is captured. a factory.
Analyzes data to understand
Example: Using descriptive
Descriptive central tendencies (mean, median)
statistics to analyze customer
Statistics and dispersion (standard
satisfaction scores from surveys.
deviation).
Example: Conducting MSA to
Measurement Ensures the measurement
validate the accuracy of a
System Analysis process is accurate and free from
thermometer used in
(MSA) errors.
pharmaceutical production.
Monitors process stability and Example: Using a control chart
Control Charts variation over time, detecting to track the weight variation of
issues before they escalate. packaged products.
Example: Using Pareto analysis
Identifies the most significant
to identify that 80% of customer
Pareto Analysis problems based on the Pareto
complaints stem from 20% of
principle (80/20 rule).
issues.
Example: A histogram showing
Shows the distribution of data,
Histogram the distribution of lead times in a
helping to visualize patterns.
supply chain process.
Example: A run chart used to
Displays data points in a time monitor the number of defects
Run Charts
sequence to identify trends. produced by a machine over
time.
Example: A box plot comparing
Helps compare distributions and
Box Plot delivery times for different
identify outliers.
distribution centers.
KPI (Key Example: KPIs for a
Measures critical performance
Performance manufacturing process,
areas in the process.
Indicators) such as cycle time and defect rate.
Analyze Phase
Identify root causes
Key Tools Description Examples
A process used to identify Example: Conducting RCA for
Root Cause
the primary cause of a high employee turnover in a
Analysis (RCA)
problem. retail organization.
Categorizes potential
Example: A fishbone diagram
causes into 6 groups (Man,
Fishbone Diagram to identify the root causes of
Machine, Material,
(Ishikawa) defects in a product assembly
Method, Measurement,
line.
Environment).
Investigates relationships Example: Regression analysis
between independent and to determine the effect of
Regression Analysis
dependent variables to marketing spend on product
establish cause-and-effect. sales.
Example: Hypothesis testing
Used to test assumptions
to compare whether a new
Hypothesis Testing and evaluate potential
training program improves
cause-effect relationships.
employee performance.
Example: Scatter plot to
Helps in visualizing
analyze the relationship
Scatter Plot correlations between two
between advertising budget
variables.
and sales growth.
Identifies failure modes in Example: FMEA for a medical
FMEA (Failure
a process and their device manufacturing process
Modes and Effects
potential effects to to identify potential failures in
Analysis)
prioritize risk. the design phase.
Example: A box plot used to
Compares distributions
Box Plot compare the delivery times
across different categories.
between different suppliers.
Helps prioritize issues or Example: Using a Pareto chart
Pareto Chart causes based on their to prioritize production
frequency or impact. bottlenecks in a factory.
A simple method to
Example: 5 Whys analysis for
5 Why identify the root cause by
a delay in product shipment.
asking "Why?" iteratively.
Identifies factors that Example: Analyzing factors
Control Factor have the most significant such as temperature and
Analysis impact on process humidity that affect the
variation. quality of a chemical process.
Improve Phase
Develop and test solutions
Key Tools Description Examples
Generates a wide range of Example: Brainstorming solutions
- Brainstorming potential solutions to address to reduce energy consumption in a
the root causes. manufacturing plant.
An experimental approach
- Design of Example: DOE used to identify the
to understand the effects of
Experiments optimal combination of ingredients
various factors on process
(DOE) for a food product.
performance.
Tests a solution in a
Example: Running a pilot test for a
controlled environment to
- Pilot Testing new software tool in a department
assess feasibility and
before company-wide deployment.
effectiveness.
Evaluates the forces for and Example: Force field analysis for
- Force Field
against a proposed change to implementing a new customer
Analysis
understand change resistance. service procedure.
Compares the benefits of an Example: Performing a cost-benefit
- Cost-Benefit
improvement against its costs analysis before investing in new
Analysis
to ensure feasibility. equipment.
Uses modeling to simulate Example: Simulation to predict how
- Simulation
processes and predict the a change in supply chain strategy will
Tools
outcome of changes. affect inventory levels.
Focuses on incremental
Example: A Kaizen event to reduce
- Kaizen Events improvements in a short time
waste in a production line.
frame.
Identifies value-adding and Example: VSM to improve the
- Value Stream
non-value-adding activities to process flow in a hospital emergency
Mapping (VSM)
eliminate waste. room.
Focuses on identifying Example: Reverse brainstorming for
- Reverse
causes that could worsen the eliminating potential failures in a
Brainstorming
problem to avoid them. new product launch.
Identifies failure points,
- Failure Mode Example: Using FMEA to reduce
ranks them by severity, and
Effect Analysis product defects in a high-risk
develops mitigation
(FMEA) manufacturing environment.
strategies.
Example: Using poka-yoke
- Poka-Yoke Implementing mechanisms
techniques to prevent incorrect
(Mistake to prevent mistakes or defects
assembly of parts in an automotive
Proofing) from occurring.
factory.
Control Phase
Sustain improvements
Key Tools Description Examples
Example: Creating a
Defines methods for
control plan to monitor
- Control Plans maintaining improvements
post-improvement customer
over time.
service response times.
Documents standardized Example: Creating SOPs for
- Standard Operating
processes to ensure handling customer
Procedures (SOPs)
consistent performance. complaints in a retail store.
Example: Auditing an
Conducts regular reviews
accounting process to
- Process Audits to ensure compliance with
ensure adherence to new
the improved processes.
regulations.
Monitors ongoing Example: Using SPC charts
- Statistical Process performance and ensures to monitor product defect
Control (SPC) processes remain within rates during daily
control limits. production.
Provides clear visual Example: Using visual
- Visual Management indicators of process boards in a factory to
Tools performance (dashboards, track daily production
scorecards). goals and status.
Example: Applying the
Uses an iterative cycle to
- PDCA Cycle (Plan-Do- PDCA cycle for improving
make continuous
Check-Act) employee safety training
improvements.
programs.
A tool to measure
performance from Example: Using a
multiple perspectives balanced scorecard to
- Balanced Scorecard
(financial, customer, track the performance of
internal process, a service-based company.
learning).
Defines and tracks metrics Example: Setting PPMs for
- Process Performance to ensure continued the speed and accuracy of
Metrics (PPM) performance order fulfillment in a
improvement. warehouse.
Example: Using control
Helps monitor process
charts to monitor the time
- Control Charts stability by tracking
it takes to resolve
variation over time.
customer support tickets.
DMAIC Principle of Six Sigma
Define
Control Measure
DMAIC
Improve Analyze
Thank You !
BY: SUBHRANSU MOHANTY