DMAIC Basics
What does the “A” in DMAIC stand for?
Analyze
A manager replaces old equipment after finding it was the cause. Which step?
Improve
What tool looks like a fish and organizes causes into categories?
Fishbone Diagram
What is the purpose of the Improve step?
To fix the root cause
What is the purpose of the Control step?
To sustain improvements
Statement: This step ensures everyone agrees on the problem before solving it.
Define
Billy noticed poor cuts during rotation. Which DMAIC step is this?
Define
Fill in the blank: The “5 Whys” technique helps uncover the __________.
Root cause
Carlos installs sharper blades. Which DMAIC step?
Improve
Nancy schedules weekly blade inspections. Which step?
Control
Why is it risky to skip a step in DMAIC?
You may miss the real root cause
The supervisor asks “Why?” five times to find out why defects are happening. Which step?
Analyze
Name two categories typically found on a Fishbone diagram.
People, Equipment, Methods, Materials
True or False: Any solution that reduces the problem is good enough to Improve.
False — it must address the root cause
Why are refresher trainings important in the Control step?
They keep workers aligned with new standards and prevent backsliding
List all five steps of DMAIC in order
Define, Measure, Analyze, Improve, Control
A team wants to know how often machine breakdowns are causing downtime on Line 3. What data should they measure?
Frequency of breakdowns, duration of downtime, and affected output.
If a team discovers “unclear procedures” as the root cause, which Fishbone category is it under?
People/Training
Why should improvements be tested on a small scale first?
To ensure they work without creating new problems
Why should solutions always be tied to analysis findings?
You may “fix” the wrong thing
Why does DMAIC work better than “just fixing things right away”?
It solves root causes, not just symptoms
A team discovers inconsistent training is leading to recurring quality problems. How should they apply DMAIC to fix AND prevent this issue?
Analyze the training gap, Improve with better onboarding, Control with regular refreshers
Your data shows higher defects on weekends. What possible causes would you brainstorm, and which tools would you use to confirm?
Causes: Less supervision, new staff, maintenance skipped; Tools: Fishbone + 5 Whys
A plant cut rejections in half by fixing blade sharpness, but worker injuries increased. What mistake was made?
The solution fixed one issue but created another; it wasn’t fully evaluated
A team fixed defects with training, but results vary by shift. What’s missing from their Control plan?
Consistent monitoring across all shifts; accountability system