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DMAIC Process Improvement
Lean Six Sigma
Full DMAIC: Define–Measure–Analyze–Improve–Control. Cycle time and defect reduction with sustained controls.
Executive Summary
A high-value process had long cycle time and elevated defect rates. This project applied DMAIC: project charter and VOC in Define; baseline metrics and process map in Measure; root cause analysis and hypothesis tests in Analyze; pilot and implementation in Improve; control plan and SPC in Control. Outcomes: ~25% cycle time reduction and sigma improvement with sustained controls.
- ~25% cycle time reduction
- Sigma level improvement with sustained controls
- Reusable DMAIC template for future projects
Context & Problem
The process was a bottleneck; defects and rework were high. Ad-hoc fixes had not stuck. The organization needed a structured, data-driven approach (DMAIC) to define the problem, measure baseline, find root causes, implement and verify improvements, and lock in gains with controls.
Methodology & Frameworks
Define: project charter, VOC, CTQ. Measure: process map, baseline sigma and cycle time. Analyze: Fishbone, 5-Why, hypothesis tests. Improve: pilot, verify, rollout. Control: control plan, SPC, documentation.
Implementation
A Black Belt–led team executed DMAIC with weekly reviews. Baseline data was collected; root causes were validated with statistical tests. Pilots were run before full implementation. Control plans and dashboards sustained gains.
Outcomes
- ~25% cycle time reduction and defect reduction.
- Sigma improvement with controls in place.
- Reusable DMAIC deliverables for future projects.
Lessons Learned
DMAIC works when the team stays disciplined through all five phases. Validate root causes with data. Control phase is where many projects fail—document and monitor. Management support kept the project on track.