Six Sigma Project Checklist

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DMAIC (the method utilized for existing business processes):

1. Define:
   • DMAIC method is used to solve a problem with an unknown solution. On this step you need to choose a problem area and define the problem in clear measurable terms;
   • Create Problem Statement;
   • Identify the Processes involved and map them;
   • Identify and consider the voice of the customer (define the customers and their needs);
   • Identify Champion;
   • Identify Process Owner;
   • Determine Customers and their Requirements (CTQs – Critical To Quality characteristics);
   • Assemble your Six Sigma Team (specifically trained managers within a company who are responsible for quality improvement project and titled as “Black Belts”, “Green Belts”, etc);
   • Define project Goals;
   • Calculate business impact and state metrics;
2. Measure:
   • Define the key aspects of the current process (CTQs received from customers become points of critical priority);
   • Develop and implement data collection plan;
   • Collect relevant data on the process;
   • Describe the current state of the process;
   • Determine key process output variables (they are called Y’s);
   • Map the Process in its current state;
   • Determine the initial capability and stability of the project Y’s;
   • Measure Y’s;
   • Define the potential ways for process and its inputs to go wrong (use FMEA – Failure Modes and Effects Analysis);
3. Analyze:
   • Analyze the information gathered;
   • Carry out design of experiments to understand how process variables affect process results;
   • Determine performance gaps and define performance goals (for Y’s);
   • Approve cause-and-effect relationships;
   • Analyze Y’s through MSA (Measurement System Analysis);
   • Define wasted and non-wasted actions;
   • Perform Variance Component Analysis for Y’s;
   • Figure out the Sources of Variation;
   • Seek out root cause of the defects;
   • Benchmark best practice (Y’s);
   • Identify key drivers (X’s);
   • Determine the major X’s and Y=f(x) Relationship;
   • Perform Measurement System Analysis for X’s;
4. Improve:
   • Develop improvement hypotheses and link them with potential solutions;
   • Study process capability improvement;
   • Define accepted tolerances and assess failure modes of potential solutions;
   • Characterize and optimize the process as required;
   • Approve and validate potential improvement via Pilot implementation;
   • Verify process capability improvement;
   • Test and amend hypotheses;
5. Control:
   • Develop validate monitoring and control system;
   • Develop and update control plans, standards and procedures;
   • Establish control charts for X’s;
   • Create workflow specifications, explain operating tolerances and train participants;
   • Put in place statistical process control and mistakes proofing;
   • Monitor business metrics to make sure the process achieves a higher level of results;

DMADV (the method for creating new product or process designs):

1. Define design goals coming from customer demands and aligned with the enterprise strategy;
2. Measure:
   • CTQ’s;
   • Product Capabilities;
   • Production Process Capability;
   • Risks;
3. Analyze to develop:
   • Design alternatives to reduce defects;
   • A high-level design;
   • Design capability;
4. Design Details:
   • Optimize the design to work at its peak;
   • Plan for design verification;
   • Simulations and modeling;
5. Verify:
   • The Design conception through...

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