Featured Product
This Week in Quality Digest Live
Six Sigma Features
Cameron Shaheen
Avoid the perfect storm of motion waste, transportation waste, and time waste
David Isaacson
Best practices for conducting effective root cause analysis in manufacturing
David Cahn
Your supply chain must be agile and responsive to the changing needs of your customers
James Wells
If the solution is obvious, just do it!
Gregg Profozich
Six Sigma principles and tools

More Features

Six Sigma News
Is the future of quality management actually business management?
Too often process enhancements occur in silos where there is little positive impact on the big picture
Collect measurements, visual defect information, simple Go/No-Go situations from any online device
Good quality is adding an average of 11 percent to organizations’ revenue growth
Floor symbols and decals create a SMART floor environment, adding visual organization to any environment
A guide for practitioners and managers
Making lean Six Sigma easier and adaptable to current workplaces
Gain visibility into real-time quality data to improve manufacturing process efficiency, quality, and profits
Makes it faster and easier to find and return tools to their proper places

More News

Steven Ouellette

Six Sigma

Project Selection for DMAIC

Guidelines to help your project succeed

Published: Monday, April 20, 2009 - 08:08

One of the most frequent questions I get from Black Belts and Green Belts I train is about the characteristics of a good Six Sigma project, particularly a first project. Define, measure, analyze, improve, control (DMAIC) is a procedure that is useful for certain types of projects and terrible for others (click on the linked text below to see why).

I have asserted before that defining Six Sigma itself is important. I said then that I have come to view Six Sigma as a general technique that uses a number of tools, some of them statistical, to solve important problems. It’s not a continuous improvement technique—contrary to what some say—but it’s a way to approach major gaps between where you are now and where you want to get to. Understanding the difference between systems, strategies, and tools, we know that DMAIC isn’t an optimal method for managing a process on a daily basis, strategic planning and policy deployment, customer quality assurance, or supplier quality assurance. However, it is a science-based method of problem-solving, so a Black Belt could easily use what they know to address problems in any of these areas.

The first and most important characteristic about a Six Sigma project is that it has a large enough effect for the business to care about. The effect may be to improve profit or safety, preserve the business market position, or anything else that the business deems important. (Sometimes I tell Black Belts in a company new to Six Sigma to ask the CEO what’s the most annoying issue they have to deal with, and then take that on as a project—strangely those projects usually succeed.) This implies a functioning strategic plan and policy deployment system so that those selecting projects can actually know what to work on to accomplish the company’s strategic objectives. 

When people don’t know the company’s strategic objectives, because they are secret and are in a folder locked in the CEO’s desk drawer, it’s a bad start to project selection. In the absence of a strong link to the business plan, any project is going to encounter problems. As part of your business case for the project, this linkage to the business plan answers the question, “Why are we working on this rather than using our time and resources to work on something else?” In the absence of alignment with the plan, you run the risk of:

  • Having resources allocated to the team pulled off when “something more important” comes along
  • Making slow progress because team members are always dealing with the crisis of the day rather than the project mission
  • Generating a low return on your training investment, causing managers to question the value of what you can do for the company
  • Accomplishing the mission, but having no one who cares

The project also needs to be focused and with a clearly-defined mission. DMAIC is too simplistic a method to be of much help in managing a complicated project with many objectives involving a lot of stakeholders, say a new capital equipment purchase. (Of course, it’s useful for solving problems that come up during such projects.). It’s really most useful when you want to improve your process or product performance on one critical metric, while keeping the others the same. Optimizing and balancing the trade-offs for a number of outputs is more of a product and process design function, and would best be handled by something like design for Six Sigma (DFSS), even on existing processes. In good DFSS implementations, there are additional tools to gather market requirements, rank product characteristics, generate alternative concepts, and develop suppliers who are able to provide the inputs to the new process. All of this requires additional training over what a DMAIC Black Belt would usually get, and so is beyond the scope of a DMAIC project.

Also beware of “mission creep,” when that nice simple mission you start off with gets “just one thing” added to it, and then another and so on, until in addition to improving the scrap rate for your process, you have to solve world hunger and the banking crisis—with no additional resources, of course.

Personally, I’m not too concerned about the time a project will take (some people say to target a project for eight months). I consulted at a location where their biggest problem only happened in the summer, so any investigations or experiments had to wait until then, and changes to the process would need another year to test out. In other situations, particularly in service industries that haven’t been examined as a process before, something as simple drawing a flow chart might show the solution to the problem, so they only need a few weeks to get a solution set up and tested.  The key is the linkage to the business plan and its timing, not a particular time span.

Six Sigma Black Belt and Green Belt projects are almost always team-based, so the problem being worked on should be one that is best addressed by a team. Teams cost a lot of money, so you need to be sure that the benefits outweigh the costs. Teams aren’t needed for tasks that an individual or a couple of people can do, nor are they good at high mental thought. They are good when the problem and its solution involve or affect a number of departments, and require analyses and critique from different disciplines. Under those circumstances, when run well, teams can come up with superior solutions than individuals.

The support and commitment of managers in the areas affected by the project is another important consideration, particularly in businesses without an existing Six Sigma infrastructure.  Managers who will be affected by the team’s decisions but don’t support the DMAIC approach can torpedo a project faster than a U-boat. In considering a project for selection, the Champion or Black Belt should be asking for a commitment from these managers, perhaps even in writing, that the resources will be available for the team, that the DMAIC process will be followed, and that the team’s decisions will be respected. This can be difficult sometimes. If the team is solving a problem that has been around for a while, the solution is likely to be something quite different from business-as-usual, which can be challenging for some people. If affected managers are going to second-guess a team that has spent months studying the problem and its potential solutions, it’s best to go somewhere else for everyone’s sanity.

Conclusions

DMAIC is a process that is powerful when applied to certain types of projects. These projects are characterized by being important and aligned with the business plan, focused on closing a clearly defined gap, using a team-based approach, and requiring resource and noninterference commitments from affected managers.

While some people advocate that the first project for a Black Belt or a Green Belt be an easy one, I personally don’t think this is a good idea. I would rather have the project flow from business needs and provide mentoring support to maximize the probability of success. If trained well and supported, the new project leader should be able to do just fine, and we avoid associating the advanced problem-solving techniques used in DMAIC with easily achieved projects.

Using these guidelines should help you select good projects that people want to see succeed, which in turn will help those working on the projects thrive in their work. In today’s economy, this can mean the difference between profiting and perishing.

Discuss

About The Author

Steven Ouellette’s picture

Steven Ouellette

Steve Ouellette, ME, CMC started his career as a metallurgical engineer. It was during this time that his eyes were opened to find that business was not a random series of happenings, but that it could be a knowable enterprise. This continues to fascinate him to this day.

He started consulting in 1996 and is a Certified Management Consultant through the Institute for Management Consulting. He has worked in heavy and light industry, service, aerospace, higher education, government, and non-profits. He is the President of The ROI Alliance, LLC. His website can be found at steveouellette.com.

Steve has a black belt in aikido, a non-violent martial art, and spent a year in Europe on a Thomas J. Watson Fellowship studying the “Evolution, Fabrication, and Social Impact of the European Sword."

 

 

Comments

DMAIC Project Selection

For a "black belt" to even ask this question points to the fallacy behind Six Sigma. Had the "black belt" truly studied under a sensei and not just taken an on line course and passed a test he/she would know to look for variation. True students of quality know that variation is the enemy. A true student of quality tells his boss what the projects should be, not the other way around.

It's quite obvious that there are a great deal of "black belts" who are still grasshoppers who have yet to snatch the pebble from Master Po's hand.