Lean Six Sigma and the DMAIC Roadmap
Accelerating Process Breakthroughts With Lean: What It Takes
Define (Organize)
- Establish Steering Committee
- Write Charter and Identify Champion
- Identify Overall Project Leader
- Establish Project Teams and Leaders
- Hold Initial Training and Kickoff Meetings
- Define Metrics and Determine Baselines
Measure (Process Data Collection)
- Document Process Maps and Product Flows
- Gather Product to Process Relationships Data (Time,Quantities, Transactions)
- Quantify Rework, Scrap, Redundancy and Optional Flow Paths
- Document Hidden Processes / Individual “Non-Formalized” Tools used
- Define Design Volumes Tied to Business Strategy (Customer Driven Capacity)
- Create Expanded SOPs
- Identify Current Quality Criteria and Related Issues
Analyze (Plan Process Layout)
- Analyze Value Added and Sequential vs. Parallel Activity
- Identify Process Families
- Calculate Takt Time and Resource Requirements
- Define Unit, Materials, or Output and Kanban / Signal Requirements
- Define Work Groupings and Operational Definition
- Create Optimized Process Flow
- Validate Process Design
- Review Future Capability vs. Business Strategy
Improve (Physical Change)
- Finalize Process Documentation
- Training of Supervisors and Individuals working in the Processes
- Implement Signal and Kanban Strategy
- Physically Change Process Layout
- Implement Employee Flexibility and Training Plan
- Create SOPs, Visual Work Methods
- Verify Flow Meets Expectations
- Link Cross Functionally
Control (Maintain Lean Six Sigma Operation)
- Ongoing Training and Reinforcement Plans, with Employee Certification
- Verify Training to SOPs and Use of Work Methods at Each Operation
- Ongoing Metrics and Reporting Responsibilities
- Implementation of Control Charts and Monitoring
- Verify Change Control Process
- Daily Operations Management
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