In Lean 6 Sigma methodology, projects are performed with basically two different road maps.
One of them is DMAIC; where the current process or product/service is improved according to customer expectations. DMAIC stands for Define, Measure, Analyze, Improve and Control phases.
The other method is used when there is no product/service or process available. This method is called DMEDI. The phases of DMEDI are Define, Measure, Explore, Develop and Implement.
DMAIC Road Map:
Define: Project scope, customer, customer expectations, process, risks and target are defined and team work starts here. At the end of this phase, the team may obtain some quick benefits regarding the project.
Measure: The phase when detailed measurements are done as per the process and customer expectations and the current situation is presented with the help of the data. In this way, the project team determines the target more clearly because the problematic areas in the process have already been identified.
Analyze: The phase when the potential root causes of the problems are determined and proved with statistical methods. At the end of this phase, root causes to be solved are decided.
Improve: The phase when alternative solutions are found for the root causes of the problems and these solutions are evaluated and the most appropriate solution(s) are determined. When the improvement phase ends, the solutions to be implemented becomes clear; in other words, road map is determined.
Control: At this phase, the solutions that are identified in the previous phase are implemented.
At this point, the important thing is the sustainability of the new process. Thus, the project outputs and metrics are monitored for one year after the implementation of the solutions.
DMEDI Road Map
Define: The phase when the subject and scope of the project are clarified and risks are identified. During this phase, the project team performs market research, when necessary.
Measure: The phase when the customer, customer expectations and targets are defined. Visits, survey studies and compare studies to understand the customer expectations are performed during this phase.
Explore: The phase when different concepts are developed to meet the customer expectations and one of the alternative concepts is selected.
Develop: A detailed design of the selected concept is performed during this phase. Detailed process maps, job definitions, detailed specifications of the raw material and the product, detailed information systems needs are some of the operations that should be performed during this phase. Simulation and modeling tools can be used during this phase.
Implement: The phase when the new process/service/product is put into practice and application is initiated.
Just like in DMAIC, the important point is the sustainability of the implementations.
Lean 6 Sigma Roles
Reports to Top Management,
Works for the deployment of Lean 6 Sigma Culture around the company,
Other duties; Prioritization of the projects, coordination of the project selection, and monitoring the implementation of the project in line with the success criteria.
Master Black Belt
Works full time.
Responsible for the long-term technical vision of Lean 6 Sigma,
Responsible for the training and guiding of the Black Belts.
Works full time,
Trains the Green Belts and Expert Green Belts,
Manages the project team,
Cooperates with the management for the projects and provides them with guidance and recommendations,
Uses Lean 6 Sigma methods and tools.
Black Belt Training lasts for 5 weeks (25 days).
Expert Green Belt
Practices Lean 6 Sigma methodology in the daily life,
Manages small scaled projects.
Expert Green Belt Training lasts for 5 days.
Spends 20% of his/her time for project operations,
Contributes to continuous development,
Participates in projects, when applicable.
Overcomes obstacles that are difficult to solve, provides help for the project to succeed,
Provides leadership for the identification of the project topics and determination of the priorities,
Inspires and guides.
Applies the solutions of the project process,
Owns the operation,
Is responsible for providing the sustainability of the gains.
Determines specification method for project costs and advantages,
Audits project benefits,
He/she is independent from the project team.