# The DMAIC Methodology in Six Sigma

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Six Sigma is a quality improvement approach created in early 1980s. Thanks to the efforts of engineer, Bill Smith, working in Motorola in the 80s, this approach has found its way into mainstream business. Today, it has become one of the most common methodological practices used to improve business processes, product quality, enhance customer satisfaction and increase overall profitability. Over the years, although the Six Sigma approach has been refined, the goal has remained the same: to improve business processes by eliminating the causes of errors leading to defects in a service or a product.

To accomplish this, a combination of management philosophy, a set of statistical tools and a problem-solving approach must be employed to eliminate errors and provide systems. People who work with Six Sigma practices work at different levels of accomplishment: Yellow Belt, Green Belt, Black Belt, and Master Black Belt.

The Six Sigma methodology was based on the bell curve created by Carl Frederick Grauss in the 19th century. In the 1920s, a founder member of the Institute of Mathematical Statistics, statistician Cark Shewhart, showed that the process had deviated from the mean by 3 sigmas and had to be corrected. Fast forward to the 1970s, Art Sundry, Senior Executive at Motorola, complained that there was a lack of consistent quality products in the company. Bill Smith responded to the complaint by implementing the six sigma methodology in 1986. Over time, other management improvement strategies influenced the system like Zero Defects and Total Quality Management.

In this article, we discuss the DMAIC framework and provide an overview of the steps in each phase and the tools that can be used in each phase.

## The DMAIC framework

To improve business processes systematically, the DMAIC framework can be used. DMAIC is a data-driven and effective five-step approach that works on eliminating expensive variation from the manufacturing and business processes. It stands for Define, Measure, Analyze, Improve, and Control. This methodology was designed for delivering the best performance without any defects and with competitive quality costs.

Let us discuss the five phases of DMAIC:

## Define

This is the first step in which we identify the customers, internal and external deliverables of the customer and the goal of the project will be defined. The primary focus of this phase is selecting high-impact projects and metrics that will be reflecting the success of the project. During this phase, questions like who the targeted customers are, what their requirements regarding products and services are, and what their expectations are, are asked. Also, the boundaries of the project are defined. Along with this the start and stop points, as well as the process flow, need to be mapped out during this phase.

### Steps in the Define phase

• Defining Customers and requirements (CTQs)
• Defining resources
• Developing a high-level process map
• Developing milestones and project plan
• Developing problem statement, benefits and goals
• Prepare a project charter
• Evaluating key organization support
• Identifying team, process owner, and champion

### Tools that can be used in the Define phase

• CTQ Definitions
• DMAIC Work Breakdown Structure
• Process Flowchart
• Project Charter
• SIPOC Diagram
• RACI Diagram
• Stakeholder Analysis
• Voice of the Customer gathering

## Measure

This is the second phase of the DMAIC where the current process must be documented. This also includes validating the forms of measurement and assessment of the performance of the baseline. This step is similar for determining shortfall by using a customer survey. In this phase, we collect data from different sources for determining the type of defects and metrics. The most important tools that can be used in this phase are basic Pareto charts, process capability measurement, Gage R & R, and process flowcharts.

### Steps in the Measure phase

• Developing data collection plan
• Collecting the data
• Beginning Developing y = f(x) relationship
• Defining unit, opportunity, and defect
• Detailing the process map of different, appropriate areas
• Determining sigma baseline and process capability
• Validating the measurement system

### Tools that can be used in the Measure phase

• Benchmarking
• Data Collection Plan/Example
• Measurement System Analysis
• Process Flowchart & Value Stream Map
• Process Sigma Calculation
• Voice of the Customer Gathering

## Analyze

The primary focus of the Analyze phase is the filtration of the topmost causes of the Critical-to-Quality Characteristic or the CTC metric for examination. Usually, for being successful, there should not be more than three causes that require control. If there are more than three causes, it means that the isolation of the critical causes was not done properly. The other reason behind this can be that the project’s goal is way too ambitious. In this step, you will have to identify if there is any gap present between the goal performance and the current performance. Sources of variation and opportunities for priority improvement needs to be identified as well. There are several tools that can be used for this phase including scatter diagrams, hypothesis testing, multi-vari analysis, time series plots, fishbone diagrams, histograms, and Pareto charts.

### Steps in the Analyze phase

• Defining performance objectives
• Determining important few x’s and y=f(x) relationship
• Identifying value as well as non-value added process steps
• Identifying sources of variation
• Determining root causes
• Prioritize the root causes

### Tools that can be used in the Analyze phase

• 5 Whys
• Cause and Effect
• Fishbone Diagram
• Histogram
• Hypothesis Testing
• Non-Normal Data Analysis
• Pareto Chart
• Process Map Analysis and Review
• Regression Analysis
• Run Chart
• Scatter Plot
• Statistical Analysis
• Time Series

## Improve

This is the fourth step of the DMAIC framework that ensures an understanding of all the causes that were identified in the Analyze phase. The aim of this phase is eliminating and controlling the causes for achieving the required breakthrough performance. Now, discipline and technology are used for designing creative and innovative solutions that will be fixing as well as preventing problems. You will also have to develop and deploy an implementation plan. For this phase, you can use tools like Hypothesis Testing, Regression Analysis, Design of Experiments (DOE), and Analysis of Variance (ANOVA).

### Steps in the Improve phase

• Assessing potential solution’s failure modes
• Correcting or re-evaluating potential solutions
• Defining the potential system’s operational tolerances
• Developing potential solutions
• Performing design experiments
• Validating potential improvements through pilot studies

### Tools that can be used in the Improve phase

• 5 S
• Brainstorming
• Design of Experiments
• Failure Modes and Effects Analysis
• House of Quality
• Mistake Proofing
• Pugh Matrix
• QFD
• Simulation Software

## Control

In this last phase, you have to ensure that all the improvements that were made must be controlled for ensuring sustained changes and lasting results. In the case of best controls, there will be a need for little to no monitoring such as irreversible product changes and process design. But there are always some process setting, setup procedures, or some other improvements that will make the daily operation and monitoring requirements necessary. Steps need to be taken for ensuring that the process doesn’t revert to the old way.

### Steps in the Control phase

• Closing project and finalizing documentation
• Defining and validating control system and monitoring
• Determining process capability
• Developing handoff to process owner and transfer plan
• Developing procedures and standards
• Implementing statistical process control
• Verifying cost savings/avoidance, benefits, and profit growth

### Tools that can be used in the Control hase

• Control Charts
• Control Plan
• Cost Savings Calculations
• Process Sigma Calculation

Each of the five DMAIC phases come together in the implementation of six sigma, which can turn the business around for any organization.

## Implementation of DMAIC

In this section, we will take a look at two examples of DMAIC implementation that use varied continuous improvement models for specific applications:

### Floor yield improvement in a manufacturing shop

The first example is of a repetitive manufacturing process, where the yield is increased by making products:

• Define: Identify the product flow, the specific products, and the goal
• Measure: Define the metrics that will be used as the first-pass yield, rolled first-pass yield, or OTIFNE; it will also include monitoring for time to gather baseline data that is statistically meaningful.
• Analyze: Look for trends, assess the standard deviation and mean from data, address, and identify outliers; this also includes identifying variables impacting the yield using root cause analyses.
• Improve: Define and put in place countermeasures o address the identified root causes; monitor the process to confirm the achievement of desired yield improvement.
• Control: Implement measures to maintain improved performance.

### Impact on Hospital outcomes through evidence-based care

The second example shows how improvements can be driven in a hospital through observation and usage of principles of Lean in a DMAIC framework:

• Define: Ask questions like how often infections occur in a hospital, over what time frame will infection’s treatments will improve.
• Measure: Measuring the current state
• Analyze: Determine the root cause like the procedures introducing contamination and specific process steps.
• Improve: Implement a checklist like basic hygiene steps, sterile barriers, disinfectants, enhancing equipment, and avoiding susceptible areas.
• Control: Incorporate reinforcement and training to internalize the process and improve the culture; this can also include empowerment of nursing staff to ensure enforcement of the measures introduced.

Conclusion

According to the six sigma level, only 3.4 defects out of one million products or services are acceptable. To achieve this, continuous efforts are made to the point where predictable results and stable products are achieved.

As discussed above, the six sigma methodology deconstructs the process of manufacturing to its smallest, essential parts. It then works on defining and evaluating every step of the process and searches for ways to improve efficiencies in the structure of the business. This is done to both improve the process quality and increase the bottom-line profit.

With a good overview of the DMAIC framework, you can now work towards becoming proficient in the six sigma methodology. Start with the Yellow Belt or move up the Green Belt and Black Belt to the Master Black Belt.

### KnowledgeHut

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KnowledgeHut is an outcome-focused global ed-tech company. We help organizations and professionals unlock excellence through skills development. We offer training solutions under the people and process, data science, full-stack development, cybersecurity, future technologies and digital transformation verticals.
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## Essential Guide to Six Sigma Green Belt Certification

What is Six Sigma Green Belt? A Six Sigma Green Belt is a professional who has a thorough understanding of the advanced elements of the Six Sigma Methodology. Green Belts lead improvement projects and also act as team members to be part of more complex improvement projects that are led by Black Belts.  Being well versed in all aspects of Six Sigma Methodology, a Six Sigma Green Belt is competent in subject matters of DMAIC (Define, Measure, Analyze, Improve and Control). A Green Belt certified professional is highly proficient in implementing, performing, interpreting and applying Lean Six Sigma. Who is eligible for the Six Sigma Green Belt? Being a people-driven process, the performance levels of a Six Sigma project are dependent on the expertise, commitment, and persistence of individual team members. When considering the roles that provide a contribution to the project, only the higher roles like that of Black Belt are often considered. However, Green Belts also have a crucial role in improving the performance of projects. Green Belts are efficient team members and their objective is improving process quality. They help in bridging the gap between the real-world application and theory behind Six Sigma. They play an important role in process improvement, project management and data inspection. A Green Belt certification training teaches the candidates about the basic tools that a project team uses and application of DMAIC skills relative to a Six Sigma project. Six Sigma Green Belt certification is meant for candidates who have work experience in business management or supply chain and have an interest in terminologies like waste reduction and continuous improvement. Earning the certification improves the proficiency of the candidates, making them more desirable for employers. The certification is best suited for professionals who are responsible for improving outputs, controlling costs and helping in improving results. How to get certified in Six Sigma Green Belt? Six Sigma certificate can be earned through different providers. Some major certification providers include ASQ, IASSC etc.  The following section explains the process for you to get certified in Six Sigma Green Belt,  Learn the relevant subject matter You will first need to learn the relevant subject matter, appear for and pass an examination that tests proficiency and competency in a hands-on environment. You will then need to purchase learning materials to train online or enrol into a classroom training course provided by an accredited training school.  Pass a written examination The next step is to pass a written examination consisting of multiple-choice questions and secure For the IASSC Certified Lean Six Sigma Green Belt Exam™, you will need to attempt a 100 question, closed book, proctored exam within a 3-hour period.  Complete Quality projects On securing a score of 70% or more, you must complete quality projects related to the concepts of Green Belt. You will then be awarded the professional designation of IASSC Certified Green Belt (IASSC-CGB™) from the International Association for Six Sigma Certification. What are the roles and responsibilities of a Six Sigma Green Belt? A Green Belt is an employee of an organization who has training on the improvement methodology of Six Sigma. The main aspect of their full-time job is leading the process improvement to get high-quality products or services. Green Belts spend a considerable amount of time on strategy building and decision-making components of the Six Sigma project planning process.  With a thorough knowledge of the overall process, they help deliver feedback and driving performance goals by working with centralized project managers. The main responsibilities of a Six Sigma Green Belt are:Lead the project team of Six Sigma improvement Work under a Six Sigma Black Belt’s supervision. Analyze quality problems and solve them Work in coordination with the project’s data collection process team and provide validation to the measurement system Green Belts operate within the limits of their functional area Assist in the improvement of team facilitation skills Develop Project charter along with Supplier, Input, Process, and Output (SIPOC) Diagram for the project What are the benefits of Green Belt Certification? Professional development Earning Green Belt certification equips you with different skills that help the organization you are working for. These skills are useful in day-to-day interactions as well. The training for Six Sigma Green Belt makes you capable and confident enough to discuss complicated subjects, solve problems in an effective manner and provide helpful recommendations Financial advantages When you earn Green Belt certification, you have the confidence of finishing projects effectively and reducing costs of operation for your organization. Generally, organizations need to pay reserve funds for every project for timely completion of project and getting positive output from the project. However, it might not be needed to use reserve funds if Six Sigma Green Belt principles are implemented properly. Benefits to the customer A Green Belt expert can help in providing better products and services, thus ensuring the loyalty of the customers. A lot of clients look for companies making use of Six Sigma. Green Belt experts improve the reliability of an organization, attracting new customers with the assurance of best quality products or services. Competitive advantage Six Sigma can be applied in the sales pitch and advertisement of your business too. By getting a Six Sigma Green Belt certification and implementing Six Sigma, you can help maintain a performance level that is ahead of the competitors. Six Sigma provides you with the required confidence and expertise. It revolves around accumulating information and investigating, which is why the decision-making process won’t be that complex. Six Sigma Green Belt Certification Exam Requirements The requirements to get Six Sigma Green Belt certified are mentioned below: Work experience A Green Belt is an employee who spends some time as a part of process improvement teams. They perform the job of analysing and solving quality problems. They are usually involved with quality improvement projects like Six Sigma. To get Green Belt certified under ASQ, you need to have a work experience of at least three years in an area or more in the Body of Knowledge of Six Sigma Green Belt. The IASSC certification does not have any prerequisites. The job has to be a paid, full-time one. Co-op, paid intern or other course works are not applicable for the work experience requirement.For the CSSC certification, there are no prerequisites. Education:There are no educational waivers granted. Expectations A certified Six Sigma Green Belt is expected to: Operate in the supervision of or in support of a Six Sigma Black Belt Solve and analyze quality problems Be involved in quality improvement projects Has a work experience of minimum three years Be capable of demonstrating their understanding of tools and processes of Six Sigma. Exam format Six Sigma Green Belt Here is the exam format for Six Sigma Green Belt for all the Accrediting bodies: ASQType of questionsNo of questionsDurationOpen/closedMCQ110 for computer 100 for paper-based Four and a half hour Four hoursOpen bookIASSCType of questionsNo of questionsDurationOpen/closedMCQ and True/False100Three hoursClosed bookCSSCType of questionsNo of questionsDurationOpen/closedMCQ and True/False100Non-TimedOpen bookHow to apply for Six Sigma Green Belt exam? In the section to follow, we guide you through the certification process through the International Association for Six Sigma Certification (IASSC), the Council for Six Sigma Certification (CSSC) and the American Quality for Quality (AQS). Certification from the International Association for Six Sigma Certification (IASSC)  For the IASSC Certified Yellow Belt, you have to apply for the ICYB exam, take the exam, and achieve a passing score. To apply for the exam, you will be contacting your KnowledgeHut representative who will order the exam voucher. The certification fee is not included in the course fee. After this, you will be able to take the exam. Certification from the American Society for Quality (ASQ) While applying for the ASQ Six Sigma Green Belt exam, you have two options: Computer-based exam This is a one-part exam is offered only in English and it consists of 110 questions and has a duration of four and a half hours. Paper-based exam This one-part exam consists of 100 questions and has a duration of four hours. This exam is offered in English, Mandarin and Spanish, based on specific locations. Depending on what you prefer, you can visit your exam provider’s website and apply for the exam by following relevant steps. Prometric is one such testing partner. Here is how you can schedule your exam. Go to Prometric’s official website. Click on Schedule Your Exam present under the Test Takers section. Search for ASQ in the search bar. Click on Read More. Under the Actions table, select the Schedule option. Select your Country. On the next page, Read Information Review and hit Next. Agree to the Privacy policy and click on Next. Enter your Eligibility ID and other details. Next, select Yellow Belt in the appointments section. Select a suitable date and time for the exam. Your exam will be scheduled. Certification from the Council for Six Sigma Certification (CSSC) For the CSSC Six Sigma Green Belt exam, follow the below-mentioned steps: Visit the link. Click on ‘Add to cart’. A pop-up will appear. You will see the options ‘View Cart’ or ‘Checkout’. Select the Checkout option. Fill in the details.  Complete the payment. Your order will be placed. How long does it take to get my Green Belt certification exam results? It is always important to be promptly notified of the exam results. The results are usually provided in quick time. If you have taken the IASSC Certified Lean Six Sigma Green Belt Exam™, you will be provided your results through email within 1 to 2 days after giving the exam. If you pass the exam, you will be getting a certification from the IASSC. What is the average salary of Six Sigma Green Belt certified professionals? The Green Belt certification is for a mid-managerial role that involves implementation of Six Sigma methodologies. Positions that a Green Belt may undertake include: Process Engineer Quality Assurance Manager Quality Manager Supplier Quality Engineer Continuous Improvement Manager. According to a study revealed by Indeed.com over 12 months from more than 222,000 data points, the range of average annual salary for a Lean Six Sigma Green Belt certified professional is from $71,381 per annum to$101,869 per annum. A Six Sigma Green Belt earns around $72,000 per year on an average. According to PayScale.com the average annual salary for a Green Belt certified individual is approximately between$65,000 per annum and $79,000 per annum. The annual salary also tends to vary based on the Green Belt role. Average salary for a Process Engineer is$73,166, Quality Manager is $79,141, Continuous Improvement Manager is$77,141, and a Quality Assurance or Quality Control Engineer is \$66,030 per annum. *All the figures are from Indeed.com's salary estimation based on job advertisements and 512,851 employees.Gain competence in applying the Six Sigma philosophy. Check out our latest courses here and get the personalized guidance you need.
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Essential Guide to Six Sigma Green Belt Certificat...

What is Six Sigma Green Belt? A Six Sigma Green B... Read More