DMAIC
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DMAIC is the five-phase problem-solving methodology used in Six Sigma: Define, Measure, Analyze, Improve, and Control.
Definition
DMAIC is the core problem-solving methodology of Six Sigma, consisting of five phases: Define, Measure, Analyze, Improve, and Control. Each phase builds on the previous one, creating a structured approach to identifying root causes and implementing sustainable solutions. Unlike ad-hoc problem-solving, DMAIC requires data-driven decisions and statistical validation at each stage, ensuring that improvements are based on evidence rather than assumptions.
Examples
A packaging line had excessive downtime. In Define, the team scoped the problem to one machine. Measure revealed 45 stops per shift. Analyze identified worn bearings as the cause. Improve implemented predictive maintenance. Control established weekly vibration monitoring. Downtime dropped 80%.
Key Points
- Define: Clarify the problem, scope, goals, and customer requirements (CTQs)
- Measure: Collect baseline data and validate the measurement system
- Analyze: Use statistical tools to identify root causes
- Improve: Develop, test, and implement solutions
- Control: Sustain gains with monitoring, documentation, and response plans
Common Misconceptions
DMAIC is just common sense with fancy names. While the concepts seem intuitive, DMAIC's power lies in its rigor—requiring data validation, statistical analysis, and control mechanisms that prevent backsliding. Without this discipline, most improvement efforts fail to sustain results.
You can skip phases if you already know the answer. Jumping to Improve without proper Measure and Analyze often leads to solving the wrong problem. Data frequently reveals that initial assumptions about root causes are incorrect.