How Lean fits within the DMAIC Methodology

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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