DMAIC - List of Tools

Phase - Define
The purpose of the define step is to allow the project team to produce,
amongst others:
A project charter or initiation document
High level process maps
Stakeholder analysis
Tool
What the tool is used for
When to use
Coaching points
PROJECT / TEAM
CHARTER
Project Scope & Business Case

Team Selection & Rules
Develop at start of
project, on-going
Living document, clearly written,

define scope
http://www.mindtools.com/page
s/article/newTMM_95.htm
HIGH LEVEL PROCESS

MAPS
Process mapping is a technique for

making work visible.
Develop at start of
project, on-going
The team exercise of building

the map and seeing the process
globally are the factors that are
critical for success rather than
what the actual map looks like
in the end.
http://www.ahrq.gov/qual/project
red/swimlane.htm
STAKEHOLDER
ANALYSIS
Engaging the right people in the right

way in your project
Develop at start of
project, on-going
http://www.mindtools.com/page
s/article/newPPM_07.htm
Phase - Define
Tool
When to use
Coaching points
Value Stream Map
Visualizing Work Processes
Planning Tool
http://www.bizbodz.com/BusinessImprovement/Lean/Value-StreamMapping-How-to-Guide-Part-1.asp
http://www.strategosinc.com/value_s
tream_vs_process_mapping.htm
Value Stream Analysis
Value-added Flow Chart
CRITICAL CUSTOMER
REQUIREMENTS & KANO
ANALYSIS
Quantifies VOC
After VOC has

been captured
Transforms VOC to measurable

requirements.
http://kanomodel.com/
EFFECTIVE TEAM
BUILDING
Transforms individuals into

performing team.
Beginning, ongoing
Critical to project success.

Building and Leading High
Performance Teams - Teambuilding |
Inc.com
Project Selection
Align projects with Organizational

strategy
Beginning, ongoing
http://www.tutorialspoint.com/manag
ement_concepts/project_selection_
method.htm
2
Phase - Define
Tool
When to use
Coaching points
SIPOC
Outline elements of the process
Develop at early stage of

project
Establish inputs and outputs

involved in a process
http://www.isixsigma.com/tools
-templates/sipoc-copis/sipocdiagram/
FUNCTIONAL
DEPLOYMENT MAPS
Detailed sequence of all steps in

process
Develop early, revisit

often
Ensure As Is status is
captured
Can identify quick wins
http://leanyourcompany.com/m
ethods/How-to-construct-adeployment-flowchart.asp
VOICE OF THE
CUSTOMER/
BUSINESS & KEY ISSUES
Identify customer wants or needs

Identify key customer issues
Identify business issues
During Define phase
Customers may be difficult to

identify.
http://bx.businessweek.com/vo
ice-of-the-customer/
RACI
(Responsible, Accountable,
Consulted, and Informed)
A responsibility assignment matrix
Beginning, on-going
http://www.valuebasedmanage
ment.net/methods_raci.html
http://en.wikipedia.org/wiki/Res
ponsibility_assignment_matrix
http://www.dmaictools.com/dm
aic-define/raci-charts-rolesand-responsibilities-matrix
3
Phase - Define
Tool
When to use
Coaching points
Project Priority Calculator
Identify those projects that have

the highest priority
When you cant improve

every process at once
Project Priority Calculator
Process Flow Chart
The Process Flow chart provides a

visual representation of the steps
in a process
Often one of the first

activities of a process
improvement effort
Process Flow Chart
Affinity Diagram
The tool is used to consolidate a

large amount of information into
groupings or clusters of ideas that
have a natural affinity
A great tool to use when

sorting Voice of the
customer data under
broad 'Issues' categories
Affinity Diagram
FMEA
A model used to prioritize potential

defects based on their severity,
expected frequency, and likelihood
of detection
Failure Mode & Effects

Analysis (FMEA)
Phase - Measure
Measure is the heart of what makes Lean Six Sigma work:
Evaluate the existing measurement system
Improving it is necessary
Developing a measurement system if you dont already have one
Observe the process
Gather Data
Map the process in more depth
Tool
When to use
Coaching points
Input/Process/Output
Indicators
Identify what to measure and the

relationship between
measurements.
At beginning of Measure
phase
http://en.wikipedia.org/wiki
/IPO_Model
Data Collection Plan
To gather reliable and statistically

valid data
At beginning of Measure
phase
http://www.isixsigma.com/t
ools-templates/samplingdata/building-sound-datacollection-plan/
Measurement Plan
Defines sample size, frequency,

additional data to collect and how
we use the data.
Before measurement
http://www.qihub.scot.nhs.
uk/knowledgecentre/qualityimprovement-tools/datacollection-plan-form.aspx
5
Phase - Measure
Tool
When to use
Coaching points
Measurement System
Analysis (MSA)
Measurement System Analysis is

to qualify a measurement system
for use by quantifying its accuracy,
precision, and stability
To guide decisions
Measurement System
Analysis (MSA)
Sampling Techniques
Use to determine optimum sample

size.
When there is a large

population of data.
http://www.experimentresources.com/statisticalsampling-techniques.html
Measurement System
Analysis (Gage R & R,
MSE)
To understand the sources of

variation that can influence
results.
When you dont understand

the capability of the
measurement system.
http://www.moresteam.co
m/toolbox/measurementsystem-analysis.cfm
Histogram
Visual display of one variable

showing data centre, spread,
shape & outliers
1.Summarise
2.Understanding
3.Compare to spec
http://quarknet.fnal.gov/too
lkits/ati/histograms.html
http://www.youtube.com/w
atch?v=RyxPp22x9PU
Phase - Measure
Tool
When to use
Coaching points
Control Charts
Plots observations in time

sequence against a mean and
control limits.
Monitor process to control

& improve. Identify Special
Causes.
http://asq.org/learn-aboutquality/data-collectionanalysistools/overview/controlchart.html
http://www.youtube.com/wa
tch?v=zvp8qmH3Eos
Run Chart

sequence
To identify trends, shifts or

cycles over time.
http://www.shmula.com/run
-chart/3506/
http://www.youtube.com/wa
tch?v=K8q6HKrUO7I
Trend Chart
Phase - Analyze
The purpose of the Analyze phase is to make sense of all the information and
data collected:
Use data to confirm source of delays, waste, and poor quality
Biggest challenge is to stick to the data
Avoid using experience and opinions about the root cause of problems
Look for patterns in the data
Tool
When to use
Coaching points
5-Why Analysis
used to move past symptoms and

understand the true root cause of
a problem.
Related to the Cause &

Effect (Fishbone) diagram,
and can be used to
complement the analysis
necessary to complete a
Cause & Effect diagram
5-Why Analysis
Phase - Analyze
Tool
Design of Experiments
The term experiment is defined

as the systematic procedure
carried out under controlled
conditions in order to discover an
unknown effect, to test or
establish a hypothesis, or to
illustrate a known effect.
Cause and Effect Diagram

(ishikawa)
A tool for analyzing process

dispersion. It is also referred to
as the Ishikawa diagram,
because Kaoru Ishikawa
developed it, and the fishbone
diagram, because the complete
diagram resembles a fish
skeleton. The diagram illustrates
the main causes and subcauses
leading to an effect (symptom).
The cause-and-effect diagram is
one of the seven tools of quality.
Also called Fishbone

diagram
When to use
Coaching points
Brainstorming of potential
root causes of problems
(idea generation)
http://www.mindtools.com
/pages/article/newTMC_0
3.htm
Fishbone (Ishikawa)
Diagram
Phase - Analyze
Tool
When to use
Coaching points
Pareto
Define specific problem to

concentrate on its root cause
analysis (identify vital few). A
graphical tool for ranking causes
from most significant to least
significant. It is based on the
Pareto principle, which was first
defined by J.M. Juran in 1950. The
principle, named after 19thcentury economist Vilfredo Pareto,
suggests that most effects come
from relatively few causes; that is,
80% of the effects come from 20%
of the causes. The Pareto chart is
one of the seven tools of quality.
Identification of vital few

causes of particular
problem.
http://www.tutorialspoint.com/
management_concepts/paret
o_chart_tool.htm
After data collection

from measurement
phase
http://asq.org/learn-aboutquality/cause-analysistools/overview/pareto.html
A tool which is used to prioritize

potential causes by examining
their relationship with the CTQs.
The highest overall

score should be
addressed first because
they will have the
largest impact on the
CTQs.
C&E Matrix
Pareto Chart (Manufacturing

ex.)
Pareto Chart (Service ex.)
http://www.processma.com/re
source/cause_and_effect_ma
trix.htm
10
Phase - Analyze
Tool
When to use
Coaching points
Checksheet
A simple data-recording device.

The check sheet is customdesigned by the user, which
allows him or her to readily
interpret the results. The check
sheet is one of the seven tools of
quality. Check sheets are often
confused with data sheets and
checklists (see individual
entries).
To gather or collect data.
http://www.shmula.com/c
heck-sheets/3932/
Cost/Benefit Analysis
A multitude of methods used to

determine the financial impacts
of the project to the company.
In the evaluation and

selection of solutions.
http://management.about.
com/cs/money/a/CostBen
efit.htm
11
Phase - Analyze
Tool
When to use
Coaching points
A branch of applied statistics

dealing with planning, conducting,
analyzing, and interpreting
controlled tests to evaluate the
factors that control the value of a
parameter or group of parameters:
To identify factors and their

appropriate settings.
http://www.tutorialspoint.co
m/management_concepts/
design_of_experiment.htm
Histogram
A graphic summary of variation in

a set of data. The pictorial nature
of the histogram lets people see
patterns that are difficult to see in a
simple table of numbers. The
histogram is one of the seven tools
of quality.
When a picture is needed to

graphically depict variation in
data.
http://quarknet.fnal.gov/tool
kits/ati/histograms.html
Generate creative solutions to a

problem
To break out of stale,

established patterns of
thinking
Brainstorming
http://www.youtube.com/w
atch?v=RyxPp22x9PU
http://www.mindtools.com/
brainstm.html
12
Phase - Analyze
Tool
When to use
Coaching points
Hypothesis Tests (t-test,

ANOVA, Chi Square)
A procedure whereby one of two

mutually exclusive and exhaustive
statements about a population
parameter is concluded.
Information form a sample is used
to infer something about a
population from which the sample
was drawn.
To determine whether true

statistical differences exist in
two or more sets of data.
http://stattrek.com/hypothe
sis-test/hypothesistesting.aspx
Non-value-Added Analysis
Steps in the production and

delivery of a product or service
that are considered nonessential
to meeting customer's needs and
requirements (I.e., steps the
customer would not ne willing to
pay for).
When mapping process.
http://www.moresteam.co
m/toolbox/value-addedflow-chart.cfm
13
Phase - Analyze
Tool
When to use
Coaching points
Process Map
A graphical representation of the

steps in a process. Flowcharts
are drawn to better understand
processes. The flowchart is one
of the seven tools of quality.
At beginning of project to
learn about the process.
http://www.processma.co
m/resource/process_map
ping.htm
Spaghetti Diagram
A graphical tool used to depict the

physical flow of work or material
in a process.
m/resource/spaghetti_dia
gram.htm
14
Phase - Analyze
Tool
When to use
Coaching points
Regression or
Regression Analysis
A statistical technique for

determining the best
mathematical expression
describing the functional
relationship between one
response and one or more
independent variables.
Use after key factors

identified to create model
for process performance.
http://office.microsoft.com/e
n-us/excel-help/perform-aregression-analysisHA001111963.aspx
Basic Quality Tools
When you want to know

the rrelation between
variables
Regression Analysis
http://www.tutorialspoint.co
m/management_concepts/
design_of_experiment.htm
15
Phase - Analyze
Tool
When to use
Coaching points
Scatter Diagram
A graphical technique to analyze

the relationship between two
variables. Two sets of data are
plotted on a graph, with the y axis
being used for the variable to be
predicted and the x axis being
used for the variable to make the
prediction. The graph will show
possible relationships (although
two variables might appear to be
related, they might not be-those
who know most about the
variables must make that
evaluation). The scatter diagram
is one of the seven tools of
quality.
To show relationships
between two or more
variables.
http://web2.concordia.ca/Qual
ity/tools/25scatter.pdf
http://academic.brooklyn.cuny
.edu/economic/friedman/scatt
erdiagramexcel.htm
16
Phase - Analyze
Tool
When to use
Coaching points
Stratification
A process characteristic used to

divide data into subgroups to look
for changes in process
performance that might indicate
the factor is a key driver of
process performance.
When existing data shows

no patterns or key factors.
http://asq.org/learn-aboutquality/data-collectionanalysistools/overview/stratificatio
n.html
Scatter Plot or Correlation

Diagram
Scatter plots show how much one

variable is affected by another.
The relationship between two
variables is called their
correlation .
http://mste.illinois.edu/cou
rses/ci330ms/youtsey/sca
tterinfo.html
Statistical Process Control

(SPC)
The fundamental of business

iimprovement revolves around
studying and improving
underlying processes.
m/resource/statistical_thin
king.htm
Statistical Thinking

(SPC)
Six Sigma Conversion
Table
Converts Defects Per Million

Opportunities to a Sigma Level
Six Sigma Conversion

Table
17
Phase - Improve
The purpose of Improve: is to make recommendations for changes in a
process that will eliminate the defects, waste, costs, etc
Linked to the customer
Use creativity
Review existing best practices
Tool
When to use
Coaching points
Osboms Brainstorming
Idea Generation
When existing data shows

no patterns or key factors.
http://www.skymark.com/r
esources/leaders/osborne.
asp
18
Phase - Improve
Tool
When to use
Affinity Diagram
Idea Generation.
Use when you have lots

of ideas, team paralysis
Solution Mapping
Solution Mapping includes an

initial white boarding session and
top-level assessment to help
clients formalize the purpose,
requirements and uncover any
hidden implementation barriers to
the desired performance and
development solution
Idea Generation.
Coaching points
http://www.processma.com/res
ource/affinity_diagram.htm
http://www.google.com/searc
h?q=solution+mapping&hl=e
n&prmd=imvns&tbm=isch&t
bo=u&source=univ&sa=X&ei
=M6t9UNC4EMLHqQGa84C
YCQ&sqi=2&ved=0CB0QsA
Q&biw=1441&bih=656
Lateral Thinking
19
Phase - Improve
Tool
When to use
Coaching points
Mind Mapping
Mind mapping is a creative and

logical means of note-taking and
note-making that literally "maps
out" your ideas.
Note-taking.
http://www.mindmapping.co
m/
Six Thinking Hats

Technique
It is used to look at decisions

from a number of important
perspectives.
When you need to move

outside your habitual
thinking style,
http://www.mindtools.com/pa
ges/article/newTED_07.htm
Lateral Thinking
Is solving problems through an

indirect and creative approach,
using reasoning that is not
immediately obvious and
involving ideas that may not be
obtainable by using only
traditional step-by-step logic
Method for problem

solving
http://en.wikipedia.org/wiki/L
ateral_thinking
20
Phase - Improve
Tool
When to use
Coaching points
5S
5S is the abbreviated reference to

five Japanese words that govern
workplace organization and
housekeeping. The five words
are: Seiri, Seiton, Seiso,
Seiketsu, and Shitsuke
Goes hand-in-hand with

good safety practices, and
is equally applicable to
manufacturing and service
settings
5S Tool
A3 Report
A3 Reports are one-page reports

used for documenting the
necessary information needed for
progress reporting and decisionmaking
When you want to condense

the information to a single
page and visually
communicate to the reader
using graphs, charts, and
succinct bullet points.
A3 Report
Brainstorming
Brainstorming is intended to
encourage fresh thinking and
"crazy" ideas.
When you need fresh

thinking and "crazy" ideas.
Brainstorming
Corrective Action Matrix
The Corrective Action Matrix is

used by problem-solving
teams to keep track of who is
doing what - by when
To ensure action gets

implemented and someone
is responsible to make it
happen.
Corrective Action Matrix
21
Phase - Improve
Tool
When to use
Coaching points
Error proofing
Error-proofing refers to the

implementation of fail-safe
mechanisms to prevent a process
from producing defects. This
activity is also know by the
Japanese term poka-yoke, from
poka (inadvertent errors) and
yokeru (to avoid) - pronounced
POH-kuh YOH-kay.
When it is not acceptable to

make even a very small
number of defects
Error-Proofing
Kaizen is the Japanese word

for Continuous Improvement a series of ongoing incremental
improvements by teams focusing
on eliminating all forms of waste
from the operation - typically with
little capital
Kaizen is a philosophy, not

just a process, and it is a
crucial component of the
Lean Enterprise. Many
companies have
institutionalized the practice
of Kaizen by shop floor
teams, and have achieved
significant performance
advancement through the
accumulation of incremental
advancements over time.
Kaizen
Also referred to as
Poka-yoke
Kaizen
22
Phase - Improve
Tool
When to use
Coaching points
One Piece Flow
Reduced lot sizes go hand-inhand with quick set-ups. The

smaller the lot size, the better the
flow through the process. Ideally
the lot size is reduced to one.
To link processes into cells,

eliminating double-handling,
and reducing inventory and
the space it requires
One Piece Flow
Pull Scheduling
Pull Scheduling is generally

synonymous with Just-In-Time
(JIT) inventory management - a
system of production scheduling
that pulls product through the
value-stream in a continuous flow
rather than pushing it through in
batches
To eliminate overproduction,
and hence in-process
inventory - seen a
manifestation of waste
Pull Scheduling
SMED
(quick changeover)
As lean production is dependent

upon small lot sizes, small lot
sizes are dependent upon quick
changeovers. If set-ups or
changeovers are lengthy, it is
mathematically impossible to run
small lots of parts with low
inventory because large inprocess inventories must be
maintained to feed production
during changeovers.
Quick Changeover
(SMED)
23
Phase - Improve
Tool
When to use
Coaching points
System Diagrams
System Dynamics is the study of

the behavior of complex systems
- seeking to understand the web
of relationships between activities
and to identify the linkage
between cause and effect.
Use system diagrams when

you want to visually express
the dynamic forces acting
upon the components of a
process and the interactions
between those forces.
System Diagrams
TPM
TPM was developed in the 1970's

as a method of involving machine
operators in the preventive
maintenance of their machines a reaction to increasing
specialization and centralization
of the maintenance function that
had created division-of-labor
barriers between operators and
the maintenance of their
machines and equipment
When you want to tap the

knowledge and skill of the
people who work with the
equipment on a daily basis,
and gives operators a stake
in the performance of the
equipment
Total Productive
Maintenance
24
Phase - Improve
Tool
Idea Generation
Action Plan
It helps us turn our dreams into a

reality. An action plan is a way to
make sure your vision is made
concrete
http://ctb.ku.edu/en/tablec
ontents/sub_section_main
_1089.aspx
Cost/Benefit Analysis
A cost benefit analysis is done to

determine how well, or how
poorly, a planned action will turn
out.
http://management.about.co
m/cs/money/a/CostBenefit.h
tm
Gaant Chart
A type of a bar chart that is used

for illustrating project schedules.
Solution Evaluation
Criteria
Some idea of the value or merit of

a solution to a problem
When to use
Gantt charts can be used in

any projects that involve
effort, resources,
milestones, and deliveries.
Coaching points
http://www.tutorialspoint.c
om/management_concept
s/gantt_chart_tool.htm
http://www.virtualsalt.com/
creative.htm
25
Phase - Improve
Tool
Idea Generation
Pairwise Ranking Matrix
To determine the main

preferences, priorities, needs,
constraints or problems of a
person or a group on a certain
subject.
http://www.fao.org/Participati
on/ft_more.jsp?ID=3022
Force Field Analysis
Force Field Analysis is a decisionmaking technique. It helps you make

a decision by analyzing the forces for
and against a change, and it helps
you communicate the reasoning
behind your decision.
http://www.mindtools.com/pa
ges/article/newTED_06.htm
Story Board
A Storyboard provides a quick,

visual summary of a teams work.
http://business901.com/blog
1/lean-six-sigma-storyboard/
When to use
Coaching points
26
Phase - Control
The purpose of Control: is to make sure that any gains will last.
Document the new, improved procedures
Train everyone involved
Set up procedures for tracking key vital signs
Hand-off ongoing management to the Process Owner
Complete Project documentation
Put measures in place to prevent back sliding
Tool
When to use
Coaching points
Check Process
The CHECK Process was created

to give Supervisors and other
shop floor personnel a simple tool
to evaluate process conformance.
Before gathering data and

conducting in-depth research
to determine the root cause
of process instability, it is
important to verify that the
operation is being performed
according to specifications
and standards
CHECK Process
27
Phase Control
Tool
When to use
Coaching points
Control Charts
Control Chart indicates whether

the process is currently under
control (i.e., is stable, with
variation only coming from
sources common to the process),.
Use to predict future

performance
Control chart
Control Plan
The control plan is the centralized

document to keep track of the
status of all significant process
characteristics.
Standardized Work
The systematic determination and

documentation of work element
sequence and process for each
operation.
SPC
Primary tool to improve product

quality by reducing process
variation.
Control Plan
When you want to achieve a

balanced work flow, cycle
time equal to Takt time, and
high quality,.. work must be
standardized at all
operations for optimum
efficiency and consistency
Standardized Work

(SPC)
28
Phase Control
5.1 Pilot Plan
Tool
When to use
Coaching points
Pilot
Preliminary work as a test or

trial
Pilot experiments are

frequently carried out before
large-scale implementation
http://en.wikipedia.org/wiki/Pil
ot_experiment
Objective & Key Topics
To develop and execute a pilot
Before starting a pilot
http://teaching.uncc.edu/articl
es-books/best-practicearticles/goalsobjectives/writing-objectivesusing-blooms-taxonomy
Training plan
To make people aware
Before starting pilot
http://www.google.com/searc
h?q=training+plan&hl=en&pr
md=imvns&tbm=isch&tbo=u&
source=univ&sa=X&ei=CNLUIDHI4biigKrsoDoDQ&ved=
0CCgQsAQ&biw=1366&bih=
622
Success Criteria
Defining effectiveness of pilot
Before and during pilot
http://office.microsoft.com/enus/project-help/define-yourproject-goals-and-successcriteria-HA001211137.aspx
29
Phase Control
5.1 Pilot Plan
Tool
When to use
Coaching points
Proof of Concept Plan
First Version
Before starting pilot
Example:
http://www.archives.gov/recor
ds-mgmt/policy/pilotguidance.html
Gantt Chart
Aids to planning
http://en.wikipedia.org/wiki/Ga
ntt_chart
http://www.youtube.com/watc
h?v=sA67g6zaKOE
http://office.microsoft.com/enus/excel-help/create-a-ganttchart-in-excelHA001034605.aspx
Pilot Tips
Aids to planning
http://www.pilotproject.com/tip
s.aspx
30
Phase Control
5.2 Plan & Implement
Tool
When to use
Coaching points
Potential problem analysis
To address potential barriers to

solution implementation
After executing pilot plan in

control
Apply Brainstorming
techniques
Risk assessment matrix
To consider the ways in which the

objectives for process may be at risk
After executing pilot plan in

control
http://www.cip.msu.edu/Co
mFacRAM-HowtoUse.pdf
http://www.lbjsc.txstate.edu
/caso/soc/manage/forms/c
ontentParagraph/014/docu
ment/RiskAssessmentMatri
x.pdf
Controls assessment matrix
Identify activity designed to protect

from the identified high priority risks
After risk assessment in

control
http://www.iwise2.com/cont
rols-assessment-matrix
Communication Plan
To communicate change
After pilot plan in control
Critical for buy in

http://www.hieran.com/com
et/howto.html
Implementation Planning
To precisely define the

implementation of a solution.
Success relies on quality and
thoroughness of implementation plan
After communication plan

in control
http://webaim.org/articles/i
mplementation/plan
31
Phase Control
5.3 Process Integration
Tool
When to use
Coaching points
Standardization
To identify project expansion

opportunities for your solutions
Once your best solutions have

been identified.
Replicate for same process but
in different area.
Standardize for different but
similar processes.
http://www.lean.org/workshops/Wo
rkshopDescription.cfm?WorkshopI
d=20
After you have identified

replication opportunities
http://books.google.com/books?id
=Crqm2AmECD0C&pg=PA76&lpg
=PA76&dq=replication+as+lean+t
ool&source=bl&ots=46pY2YWzvL
&sig=T48CDFzt4JoyeTZKpbl2VH
2VuXI&hl=en&sa=X&ei=s9mLUJ3
BM9DWigK4vYFI&ved=0CEAQ6A
EwBQ#v=onepage&q=replication
%20as%20lean%20tool&f=false
Replication
Identifying what you need to

consider if you want to
replicate
http://www.trainingwithinindustry.n
et/SW.html
32
Phase Control
5.3 Process Integration
Tool
Cost Benefit
Analysis
When to use
Coaching points
Before setting your deployment

schedule
http://en.wikipedia.org/wiki/Cost%
E2%80%93benefit_analysis
http://management.about.com/cs/
money/a/CostBenefit.htm
http://www.dummies.com/howto/content/performing-acostbenefit-analysis.html
Process Control
Systems
Critical tool for making

improvement continuous, that
is after you have gone
As part of the detailed

implementation plan
http://en.wikipedia.org/wiki/Proces
s_control
http://www.engineeringtoolbox.co
m/process-control-systemst_32.html
33
Phase Control
5.4 Specialty Control Charts
Tool
When to use
Coaching points
EWMA
(Exponentially weghted
moving average)
Processes that provide a

continuous stream of data
For a process with

WANDERING shifts that are
not special cause
Gives weighting to most

recent data
Can be used:
-as a dynamic process
control
-as a forecasting tool
-to detect small shifts
/EWMA_chart
34
Phase Control
5.5 Closure and Recognition
Tool
When to use
Coaching points
Rewards/Recognition
Recognizing /rewarding team efforts
As a closure
activity
1001 Ways To Reward

Employees
Book by Bob Nelson
http://www.openforum.com/idea
-hub/topics/managing/article/51ways-to-reward-employeeswithout-money-1
http://www.entrepreneur.com/art
icle/224249
http://www.hrworld.com/features
/25-employee-rewards/
http://www.inc.com/guides/2010
/04/rewarding-employees-on-abudget.html
35
Statistical Tools
36
Summary of Statistical Tools 1

Tool
When to use
Coaching points
Histogram
Visual display of one variable

showing data center, spread,
shape and outliers.
1.
/Histogram
Bar chart comparison of subgroups on one variable.
To visually compare sub-groups by

individual data points and the mean.
In MINITAB 12 only. To identify
major source of variation.
/Multi-vari_chart
Summary display to visualize

differences in data center, spread
and shape across categories.
/Box_plot
Multivari Charts
Box Plots
Visual display of the summary

of Y data grouped by category
of X.
2.
3.
Summarize large amounts of

data
To get a feel for the data
To compare actual description
to customer specs
http://www.micquality.com/
six_sigma_glossary/multi_
vari_chart.htm
http://www.purplemath.co
m/modules/boxwhisk.htm
Run Charts
Plots observation in time

sequence
To view process performance over

time for trends, shifts or cycles.
Run chart - Wikipedia, the

free encyclopedia
http://www.ihi.org/knowled
ge/Pages/Tools/RunChart.
aspx
37

Tool
When to use
Coaching points
Control Charts

sequence against a mean and
control limits.
To monitor the process in

order to control and
improve process
performance over time for
trends, shifts or cycles. To
identify special causes.
http://en.wikipedia.org/wiki/Contr
ol_chart
To understand the possible

relationships between two
variables. To identify
possible root causes which
are related to Y. Do not
use with special
http://mste.illinois.edu/courses/ci
330ms/youtsey/scatterinfo.html
Scatter Diagram (Plot)
Plots a response Y versus a

predictor X.
http://www.ehow.com/how_5928
553_create-control-chartsexcel.html
http://www.youtube.com/watch?v
=-SeCPLC30_g&feature=fvwrel
38

Tool
When to use
Coaching points
Behaviorally
Anchored Scales
A response scale on which

specific points are named or
described to clarify the
differences between points.
To translate subjective or
qualitative issues into data
(discrete or continuous). To
reduce variation in the
response measured.
http://en.wikipedia.org/wiki/Behav
iorally_anchored_rating_scales
Determine if there is a
difference between two groups.
1.
Test if sample average

= specified value
2. Test if 2 sample means
are equal
3. Paired t: to reduce
variation when
comparing two sample
averages
Determine of there is a
difference among many groups. statistically significant
difference among the
groups.
http://en.wikipedia.org/wiki/Stude
nt's_t-test
difference for observed
frequencies of 2 discrete
variables.
http://math.hws.edu/javamath/rya
n/ChiSquare.html
t-Test
Analysis of
Variance
Discrete Data:
Chi Square
Determine if there are

relationships between two
discrete variables.
http://www.dummies.com/howto/content/behind-barsevaluating-employees-withbehaviorally.html
http://www.graphpad.com/quickc
alcs/ttest1.cfm
http://en.wikipedia.org/wiki/Analy
sis_of_variance
http://www.physics.csbsju.edu/st
ats/anova.html
http://bio.fsu.edu/~winn/3402L/Wi
nnCH7.html
39

Tool
Regression
Summarizes, describes,
(Linear & Multiple) predicts and quantifies
relationships.
Logistic
Regression
Design of
Experiments
(DOE)
Summarizes, describes,
predicts and quantifies
relationships.
Systematic and efficient

proactive approach to testing
relationships.
When to use
Coaching points
1.
http://en.wikipedia.org/wiki/
Linear_regression
Determine if there is evidence

of a relationship between Xs
and Ys.
2. Model data to develop a
mathematical equation to
quantify the relationship.
3. Identify root causes.
4. Make predictions using the
model.
1. Determine if there is evidence
of a relationship between Xs
and Ys.
2. Model data to develop a
mathematical equation to
quantify the relationship.
3. Identify root causes.
4. Make predictions using the
model.
To establish cause and effect
relationship between Ys and Xs.
To identify vital few Xs.
http://www.statsoft.com/text
book/multiple-regression/
Logistic_regression
http://luna.cas.usf.edu/~mb
rannic/files/regression/Logi
stic.html
Design_of_experiments
http://www.moresteam.com
/toolbox/design-ofexperiments.cfm
40
7 Basic Tools
The designation arose in postwar Japan, inspired by the seven famous weapons of
Benkei. At that time, companies that had set about training their workforces in
statistical quality control found that the complexity of the subject intimidated the
vast majority of their workers and scaled back training to focus primarily on simpler
methods which suffice for most quality-related issues.
The Seven Basic Tools stand in contrast to more advanced statistical methods such
as survey sampling, acceptance sampling, statistical hypothesis testing, design of
experiments, multivariate analysis, and various methods developed in the field of
operations research.
The seven tools are:

Cause-and-effect (also known as the "fish-bone" or Ishikawa) diagram
Check sheet
Control chart
Histogram
Pareto chart
Scatter diagram
Stratification (alternately, flow chart or run chart)
41
Resources
http://www.khanacademy.org/
Statistics Handbook
http://davidmlane.com/hyperstat/index.html
http://www.statsoft.com/textbook/elementary-concepts-in-statistics/?button=1
http://onlinestatbook.com/version_1.html
http://lib.stat.cmu.edu/
http://www.strategosinc.com/human_side.htm
http://ocw.mit.edu/index.htm (search Lean Six Sigma)
http://www.moresteam.com/toolbox/index.cfm
http://www.moresteam.com/resources/lean.cfm
http://www.itl.nist.gov/div898/handbook/quantgal.htm
http://www.leansixsigmahpo.com/tools.html
http://www.skymark.com/resources/refhome.asp
http://www.strategosinc.com/value_stream_vs_process_mapping.htm
http://www.freeleansite.com/
http://www.dmaictools.com/
http://www.statpac.org/research-library/
http://www.accountability.wa.gov/leadership/lean/default.asp
http://www.gembutsu.com/lean_faq.html
http://leanyourcompany.com/improve/What-are-the-seven-wastes.asp
http://www.micquality.com/six_sigma_glossary/process_improvement_tools.htm
42

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Phase - Define

What the tool is used for

Project Scope & Business Case

Living document, clearly written,

HIGH LEVEL PROCESS

Process mapping is a technique for

The team exercise of building

Engaging the right people in the right

What the tool is used for

Value Stream Map

Visualizing Work Processes

After VOC has

Transforms VOC to measurable

Transforms individuals into

Critical to project success.

Align projects with Organizational

What the tool is used for

Outline elements of the process

Develop at early stage of

Establish inputs and outputs

Detailed sequence of all steps in

Develop early, revisit

Identify customer wants or needs

During Define phase

Customers may be difficult to

A responsibility assignment matrix

What the tool is used for

Project Priority Calculator

Identify those projects that have

When you cant improve

Project Priority Calculator

Process Flow Chart

The Process Flow chart provides a

Often one of the first

Process Flow Chart

The tool is used to consolidate a

A great tool to use when

A model used to prioritize potential

Failure Mode & Effects

What the tool is used for

Identify what to measure and the

Data Collection Plan

To gather reliable and statistically

Defines sample size, frequency,

What the tool is used for

Measurement System Analysis is

Use to determine optimum sample

When there is a large

To understand the sources of

When you dont understand

Visual display of one variable

What the tool is used for

Plots observations in time

Monitor process to control

Plots observations in time

To identify trends, shifts or

What the tool is used for

used to move past symptoms and

Related to the Cause &

What the tool is used for

The term experiment is defined

Cause and Effect Diagram