With its DMAIC (Define, Measure, Analyze, Improve, Control) roadmap, the Six Sigma methodology provides a structured

and
systematic approach to solve business and process problems. The related toolkit is a selection of proven tools and methods that
correctly applied helps to determine, analyze and improve a problem. All well and good, however, inexperienced or newly trained
Green Belts and Belt Belts tend to lose themselves in the application of individual tools. Each tool is used separately and
sequentially rather than in the context of the overall purpose of the DMAIC approach.
In the worst case, Green Belts and Black Belts are just completing templates and do not achieve the desired outcome of a
significantly improved process. An excellent way to overcome this problem is to always keep the concept of Y = f (x) in mind when
applying specific tools along DMAIC phases. Here is the Y = f(x) story, phase by phase.

Y = f(x): Process Outcome a Result of Process Inputs

The mathematical term Y = f(x), which translates as simply Y is a function of x, illustrates the idea that the important process
outcomes (Ys) are a result of the drivers (xs) within processes. The goal of DMAIC is to identify which few process and input
variables mainly influence the process output measures. Each DMAIC phase can therefore be described by how it contributes to
this goal:
Define: Understand the project Y and how to measure it.
Measure: Prioritize potential xs and measure xs and Y.
Analyze: Test xY relationships and verify/quantify important xs.
Improve: Implement solutions to improve Y and address important xs.
Control: Monitor important xs and the Y over time.

Define: Understand Project Y and How to Measure It

Many projects start with a rather unspecific and undefined business or process problem. It is obvious that something has to be
done, but where exactly to start and what exactly to achieve is often only poorly described. Multiple tools are used during the Define
phase to get a clear understanding of the project Y (i.e., what the process problem is in measurable terms and what the project
goals are).
The project charter delivers the Y by clearly stating what the business or process problem is. It also expresses the Y as a
measurable process metric that tells how well the process is performing today (the baseline) and how performance should be after
process improvement (the goal). However, in order to reach this clear definition of the Y, the voice of the customer (VOC) and a
SIPOC diagram are needed. The voice of the customer helps to define a measurable project Y by translating unspecific customer
requirements into measurable critical-to-quality elements (also known as CTQs, which is another term for the Y). In addition, VOC is
used to verify the importance of the Y metric and to set specifications for the Y under consideration. The SIPOC (suppliers, inputs,
process, outputs, customers) diagram clearly links the project Y to the process output. The output column of the SIPOC shows
which Y is a result of the process.
Since the output column usually shows multiple Ys, VOC is again needed to determine which Y should be included in the project. In
the input column, the SIPOC provides a list of potential Xs.
The business case finally links the project Y to the so called Big Y. This means it shows how achieving the project Y contributes to
higher-level business objectives like financial targets, customer satisfaction or strategically relevant goals (on time to market, on-
time delivery, inventory level, etc.). The project team can close the Define phase when it has a measurable, clearly defined Y with
set specifications that help to distinguish between desired and not desired process performance.

Measure: Prioritize Potential Xs, and Measure Xs and Y

The Measure phase usually starts with a fishbone diagram and/or a detailed process mapping. Given the clearly defined Y from the
Define phase, the fishbone helps to identify all potential causes (xs) of this Y; the detailed process mapping also shows which
process xs mostly influence the process Y. At the end of this step, the project team should have a full picture of potential xs that it
might next have to reduce to a manageable and measurable few. The prioritization matrix or simple multi-voting techniques help to
achieve this.
It is always important to remember that the brainstorming, as well as the reduction of potential xs, happens based on process
expertise, not yet on facts and data. As the next step, the team sets up a data collection plan that allows for measuring both xs and
Y in such a way that the data collected can later be used to identify cause-and-effect (i.e., xY) relationships with the help of
graphical and statistical tools. Of course, for all xs and Ys to be measured, an operational definition and if possible a gage R&R
study should be conducted in order to guarantee reliable data.
Having the xs and Y data collected, the team would now start identifying patterns in data. Usually control charts, time series plots,
and frequency plots are used to separate common from special cause variation. Xs that influence special cause variation are
identified, and if they can be explained and avoided in the future, they are removed from the data set. Additionally, Pareto analyses
where the Y is stratified by categories of one x help to further scope the project. The final step in the Measure phase is to determine
the baseline capability of the process Y: Yield, Cpk or process sigma values indicate how well the process Y is performing today.
This also sometimes leads to re-setting the initially stated goals in the project charter.
The Measure phase ends with related data for the Y and the most important xs, where xs of special cause variation have already
been removed from the data set.

Analyze: Test X-Y Relationships and Verify/Quantify Important Xs

In terms of xs and Ys, the Analyze phase is quite simple: All graphical tools (e.g., stratified frequency plots, pie charts, scatter plots,
etc.) and statistical tools (hypothesis tests, regression analysis, design of experiments) that Green Belts and Black Belts learn
during training have just one goal: Verifying and quantifying xY relationships. The large number of different tools available is simply
because different data types (continuous or discrete) of x and Y require different tools, as illustrated in the figure below. In addition
to this data door, the tools of the process door (waste analysis, value-added analysis) supplement the quantitative data analysis
with a more qualitative analysis and confirmation of important process xs.
At the end of the Analyze phase, the critical few xs that contribute most to the problem of the process Y are known.
Analyze: Selecting the Right Tool to Verify X-Y Relationships
Improve: Implement Solutions to Improve Y, Address Important Xs
Analog to the Measure phase, the Improve phase also starts with getting a full picture. This time it is a full picture of potential
solutions that by addressing the critical few xs can help improve the Y. Brainstorming and creativity techniques help to generate
these potential solutions. In order to reduce these solutions to those that should be implemented, each solution is rated against
specific criteria. Two important criteria are how much a solution contributes to improving the Y and how much it addresses specific
xs. (Of course other criteria, like easiness of implementation, costs, etc., also are important.) Before starting the implementation of
the improved process, a failure modes and effect analysis helps to identify ways that the process Y can fail and the potential causes
(newly or previously identified xs) and how to prevent these failures from happening.
At the end of the Improve phase, short-term data (e.g., from a pilot program) demonstrates that the identified solution or solution
package has really improved the Y.

Control: Monitor the Y and Important Xs Over Time

The Control phase ensures that the new performance of the Y is sustained over time. In order to achieve this, a process
management chart is developed that shows the new process flow, offers critical check points during the process, and has
recommended actions in case the process does not continue on target. In a process management chart, the previously identified
xs are called leading indicators (i.e., checkpoints during the process) and the Y is the lagging indicator (i.e., the final checkpoint at
the end of a process cycle). Additionally, a performance measurement and monitoring system or dashboard is established that
helps the process owner to measure and control the critical leading (xs) and lagging (Y) indicators on a continuous base. Control
charts are again the best tool to show the performance of the Y over time.
After the handover of these tools to the process owner, the project is closed by evaluating the achieved results in terms of xs that
were identified and the improvement in the Y. With its DMAIC (Define, Measure, Analyze, Improve, Control) roadmap, the Six
Sigma methodology provides a structured and systematic approach to solve business and process problems. The related toolkit is a
selection of proven tools and methods that correctly applied helps to determine, analyze and improve a problem. All well and
good, however, inexperienced or newly trained Green Belts and Belt Belts tend to lose themselves in the application of individual
tools. Each tool is used separately and sequentially rather than in the context of the overall purpose of the DMAIC approach.
In the worst case, Green Belts and Black Belts are just completing templates and do not achieve the desired outcome of a
significantly improved process. An excellent way to overcome this problem is to always keep the concept of Y = f (x) in mind when
applying specific tools along DMAIC phases. Here is the Y = f(x) story, phase by phase.

Y = f(x): Process Outcome a Result of Process Inputs

The mathematical term Y = f(x), which translates as simply Y is a function of x, illustrates the idea that the important process
outcomes (Ys) are a result of the drivers (xs) within processes. The goal of DMAIC is to identify which few process and input
variables mainly influence the process output measures. Each DMAIC phase can therefore be described by how it contributes to
this goal:
Define: Understand the project Y and how to measure it.
Measure: Prioritize potential xs and measure xs and Y.
Analyze: Test xY relationships and verify/quantify important xs.
Improve: Implement solutions to improve Y and address important xs.
Control: Monitor important xs and the Y over time.

Define: Understand Project Y and How to Measure It

Many projects start with a rather unspecific and undefined business or process problem. It is obvious that something has to be
done, but where exactly to start and what exactly to achieve is often only poorly described. Multiple tools are used during the Define
phase to get a clear understanding of the project Y (i.e., what the process problem is in measurable terms and what the project
goals are).
The project charter delivers the Y by clearly stating what the business or process problem is. It also expresses the Y as a
measurable process metric that tells how well the process is performing today (the baseline) and how performance should be after
process improvement (the goal). However, in order to reach this clear definition of the Y, the voice of the customer (VOC) and a
SIPOC diagram are needed. The voice of the customer helps to define a measurable project Y by translating unspecific customer
requirements into measurable critical-to-quality elements (also known as CTQs, which is another term for the Y). In addition, VOC is
used to verify the importance of the Y metric and to set specifications for the Y under consideration. The SIPOC (suppliers, inputs,
process, outputs, customers) diagram clearly links the project Y to the process output. The output column of the SIPOC shows
which Y is a result of the process.
Since the output column usually shows multiple Ys, VOC is again needed to determine which Y should be included in the project. In
the input column, the SIPOC provides a list of potential Xs.
The business case finally links the project Y to the so called Big Y. This means it shows how achieving the project Y contributes to
higher-level business objectives like financial targets, customer satisfaction or strategically relevant goals (on time to market, on-
time delivery, inventory level, etc.). The project team can close the Define phase when it has a measurable, clearly defined Y with
set specifications that help to distinguish between desired and not desired process performance.

Measure: Prioritize Potential Xs, and Measure Xs and Y

The Measure phase usually starts with a fishbone diagram and/or a detailed process mapping. Given the clearly defined Y from the
Define phase, the fishbone helps to identify all potential causes (xs) of this Y; the detailed process mapping also shows which
process xs mostly influence the process Y. At the end of this step, the project team should have a full picture of potential xs that it
might next have to reduce to a manageable and measurable few. The prioritization matrix or simple multi-voting techniques help to
achieve this.
It is always important to remember that the brainstorming, as well as the reduction of potential xs, happens based on process
expertise, not yet on facts and data. As the next step, the team sets up a data collection plan that allows for measuring both xs and
Y in such a way that the data collected can later be used to identify cause-and-effect (i.e., xY) relationships with the help of
graphical and statistical tools. Of course, for all xs and Ys to be measured, an operational definition and if possible a gage R&R
study should be conducted in order to guarantee reliable data.
Having the xs and Y data collected, the team would now start identifying patterns in data. Usually control charts, time series plots,
and frequency plots are used to separate common from special cause variation. Xs that influence special cause variation are
identified, and if they can be explained and avoided in the future, they are removed from the data set. Additionally, Pareto analyses
where the Y is stratified by categories of one x help to further scope the project. The final step in the Measure phase is to determine
the baseline capability of the process Y: Yield, Cpk or process sigma values indicate how well the process Y is performing today.
This also sometimes leads to re-setting the initially stated goals in the project charter.
The Measure phase ends with related data for the Y and the most important xs, where xs of special cause variation have already
been removed from the data set.

Analyze: Test X-Y Relationships and Verify/Quantify Important Xs

In terms of xs and Ys, the Analyze phase is quite simple: All graphical tools (e.g., stratified frequency plots, pie charts, scatter plots,
etc.) and statistical tools (hypothesis tests, regression analysis, design of experiments) that Green Belts and Black Belts learn
during training have just one goal: Verifying and quantifying xY relationships. The large number of different tools available is simply
because different data types (continuous or discrete) of x and Y require different tools, as illustrated in the figure below. In addition
to this data door, the tools of the process door (waste analysis, value-added analysis) supplement the quantitative data analysis
with a more qualitative analysis and confirmation of important process xs.
At the end of the Analyze phase, the critical few xs that contribute most to the problem of the process Y are known.
Analyze: Selecting the Right Tool to Verify X-Y Relationships
Improve: Implement Solutions to Improve Y, Address Important Xs
Analog to the Measure phase, the Improve phase also starts with getting a full picture. This time it is a full picture of potential
solutions that by addressing the critical few xs can help improve the Y. Brainstorming and creativity techniques help to generate
these potential solutions. In order to reduce these solutions to those that should be implemented, each solution is rated against
specific criteria. Two important criteria are how much a solution contributes to improving the Y and how much it addresses specific
xs. (Of course other criteria, like easiness of implementation, costs, etc., also are important.) Before starting the implementation of
the improved process, a failure modes and effect analysis helps to identify ways that the process Y can fail and the potential causes
(newly or previously identified xs) and how to prevent these failures from happening.
At the end of the Improve phase, short-term data (e.g., from a pilot program) demonstrates that the identified solution or solution
package has really improved the Y.

Control: Monitor the Y and Important Xs Over Time

The Control phase ensures that the new performance of the Y is sustained over time. In order to achieve this, a process
management chart is developed that shows the new process flow, offers critical check points during the process, and has
recommended actions in case the process does not continue on target. In a process management chart, the previously identified
xs are called leading indicators (i.e., checkpoints during the process) and the Y is the lagging indicator (i.e., the final checkpoint at
the end of a process cycle). Additionally, a performance measurement and monitoring system or dashboard is established that
helps the process owner to measure and control the critical leading (xs) and lagging (Y) indicators on a continuous base. Control
charts are again the best tool to show the performance of the Y over time.
After the handover of these tools to the process owner, the project is closed by evaluating the achieved results in terms of xs that
were identified and the improvement in the Y.