The Six Sigma Tool Guide
Tools for D.M.A.I.C.
Define, Measure, Analyze, Improve, and Control
&
D.M.A.D.V.
Design, Verify
Six Sigma Guide
Table of Contents
D.M.A.I.C
D.M.A.D.V.
Define
This is the first phase of Six Sigma: Define the problem, goal, and deliverables.
- SIPOC Diagram (Table or SmartArt)
- Maps Suppliers, Inputs, Process, Outputs, Customers
- Create a SIPOC table to understand process boundaries
- Project Charter Template
- Documents goals, scope, team, and timelines
- Use preformatted Excel templates to define objectives
- Voice of the Customer (VOC) Table
- Captures and translates customer needs into CTQs
- Summarize survey or interview data in Excel
- CTQ Tree (Hierarchy Chart)
- Converts customer needs into measurable metrics
- Insert SmartArt to visualize CTQ relationships
- Gantt Chart (Conditional Formatting)
- Tracks milestones and project progress
- Use date-based conditional formatting for a visual timeline
- Pareto Chart (Built-in Chart or Add-in)
- Identifies most frequent issues or causes
- Use Excel’s Pareto template (based on 80/20 rule)
Measure
This is the second phase: Measure current performance, collect relevant data.
- Data Validation / Drop-Down Lists
- Ensures clean, consistent data collection
- Restrict inputs (e.g., “Pass” or “Fail”)
- Check Sheet Template
- Tracks frequency of defects or errors
- Create a tally system using COUNTIF formulas
- Histogram (Data Analysis ToolPak)
- Displays process variation
- Analyze time, defects, or measurement data distribution
- Descriptive Statistics Tool
- Calculates mean, median, SD, range
- Summarize process performance metrics
- Run Chart / Time Series Chart
- Visualizes trends over time
- Use line charts to plot daily defect counts
- Box & Whisker Plot
- Shows variation and outliers
- Compare process steps or shifts
- Control Limit Calculation
- Defines process stability
- Use formulas to calculate mean ± 3σ
Key Excel Functions: AVERAGE(), STDEV.P(), MIN(), MAX(), COUNTIF(), FREQUENCY()
Analyze
Analyze data and process to identify root causes and variations.
- Pivot Tables
- Summarize and slice large data sets
- Analyze defects by shift, location, or operator
- Pareto Chart / Bar Chart
- Highlights major contributors
- Visualize “vital few” causes
- Scatter Plot with Trendline
- Tests correlation between factors
- Plot defect rate vs. temperature or time
- Regression Analysis (Data Analysis ToolPak)
- Tests cause-and-effect statistically
- Build linear regression to predict outcomes
- ANOVA (Data Analysis ToolPak)
- Compares performance across groups
- Test if multiple machines have different averages
- Fishbone (Ishikawa) Diagram
- Identifies root causes
- Create a diagram using shapes or SmartArt
- Correlation Function
- Checks relationships between variables
- Quantify association between metrics
Key Excel Functions: CORREL(), RSQ(), LINEST(), T.TEST(), F.TEST()
Improve
Develop solutions, optimize performance, reduce defects.
- Brainstorming Matrix / Affinity Diagram
- Organize improvement ideas
- Use categories in a table or color-code ideas
- Before-and-After Comparison Charts
- Shows improvement impact
- Use combo charts to compare metrics pre- and post-change
- Simulation / What-If Analysis
- Tests process changes virtually
- Use Goal Seek or Data Tables for sensitivity analysis
- DOE (Design of Experiments) Basics
- Evaluates effect of variables
- Manually build a 2ⁿ factorial matrix
- FMEA Template
- Calculates Risk Priority Numbers (RPN)
- Use columns for Severity, Occurrence, Detection, and RPN formulas
- Cost-Benefit Analysis Table
- Quantifies expected gains
- Compare baseline vs. improved cost outcomes
Control
Maintain gains through monitoring and standardization.
- Control Charts (X-bar, R, p, u)
- Monitor ongoing process stability
- Plot upper/lower control limits dynamically
- Dashboard / KPI Tracker
- Visualize ongoing performance
- Combine charts and conditional formatting for alerts
- Checklist / Audit Sheet
- Maintain standardization
- Create a checklist for process compliance
- SPC Templates (Statistical Process Control)
- Ongoing control monitoring
- Automate calculations for control limits
- Trend Analysis / Forecast Function
- Predict future performance
- Use FORECAST.LINEAR() for time series
- Documentation Tracker
- Standardize procedures and ownership
- Maintain control plans, training logs
Key Excel Tools: AVERAGEIFS(), STDEV.S(), FORECAST.LINEAR(), TREND(),
Design Phase
Maintain gains through monitoring and standardization.
- Design of Experiments (DOE)
- Optimize design parameters and identify interactions
- Test how multiple factors (e.g., temperature, speed, material) affect output
- Pugh Matrix (Decision Matrix)
- Compare multiple design alternatives objectively
- Rate each concept against weighted criteria (cost, reliability, ease of manufacture)
- Failure Modes and Effects Analysis (FMEA)
- Identify potential design or process failures early
- Evaluate each component for Severity, Occurrence, Detection, and calculate RPN
- Process Flow Design (PFMEA)
- Anticipate process-level issues before launch
- Map and analyze every step of a new process for risks or delays
Verify Phase
Maintain gains through monitoring and standardization.
- Statistical Process Control (SPC)
- Monitor stability and capability during pilot runs
- Use control charts (X-bar, R, p, c) to ensure process consistency
- Process Capability Analysis (Cp, Cpk)
- Quantify how well the design meets specs
- Compare output distribution against specification limits
- Process Audits / Standard Operating Procedures (SOPs)
- Ensure compliance and consistency
- Validate that the new process can be replicated and sustained
Key Excel Tools: NORMSINV() and STDEV.P()