DMaiC or are there critical phases of Six Sigma projects?

(a personal approach to Six Sigma project management)

Every project has its risks to get off-track. Six Sigma projects are not exceptions. Due to its structured methodology, the existing risks are fewer, but still, some derail the project. Some phases are more vulnerable than others.

If we get through all the phases with associated risks, it will be more visible which phases require increased attention.

DEFINE: the project will be defined with its scope, goal, resources and, timeline.

The Define phase must be a solid base of the project, which otherwise is collapsing. If we are unable to select the project properly with its boundaries (not business-relevant, too small or too large to handle), to allocate the right resources, to set realistic target and timeline, and not at least, a critical factor, to receive management support and commitment, our project has high chance to fail.

MEASURE: collect the right quantity and quality data

In the Measure phase, we put all our efforts into gathering the necessary data. If we miss the target, we have to redo this costly phase, besides starting over demotivates team members. To avoid this fiasco, we have to identify the right input variables. It allows us to select which should be measured, with what sample size (how big difference we want to detect) and, how we want to analyse the data later. If we aim for reliable data, we must ensure that the Measurement System Analyses have acceptable results. The next big challenge is to create and carry out Data Collection Plan: what to measure, how long, who, how (data format) and train the people and supervise the execution.

Analyse: identify the input variable to be controlled

With a properly defined Define and Measure phase, we got on the right path, which guides us through Analyse phase: we already received the right amount and quality data, we already decided what tools we are using. Hence the chance that we have to redo the measurement since some input variables were not considered or we have to extend with some time, are significantly reduced. Still, the risk exists that we use statistical methods incorrectly.

Improve: create a solution that works

Improve phase requires the most creativity, but that is its beauty. We already identified what variables we have to control. We have to find the right, controllable and sustainable solution. If we can build reliable control (poka-yoke) into the solution, we reduce further the arising risk in the Control phase.

CONTROL: create an effective and sustainable solution

The Control phase requires rigour. Selecting an adequate control mechanism is only part of the task. We have to train employees, document changes and check effectiveness. Finally, we must celebrate the results and reward the team.

Certainly, it is only a rough sketch of the major risks, but it shows that crucial mistakes can be made in Define, Measure and Control phases.

I would be a bad storyteller, as you might have seen the “killer” in the headline.

Please share your thoughts, experiences.

(For the graphic special thanks to Sara Gránásy.)

by Péter Gránásy SixSigma Trainer