Kaizen and DMAIC: What's the differences?
Published on: August 20, 2022
Last updated: January 06, 2023 Read in fullscreen view
Last updated: January 06, 2023 Read in fullscreen view
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Let’s look at the main characteristics of each approach:
Kaizen™ – a Japanese word that simply means ‘Change for the better’. The main characteristics are:
- Projects are well defined and baseline stats are collected before starting
- Dedicated resources are subject matter experts (SMEs) and focus on only the project
- The solutions should come from the SMEs as they will need to act as champions for the change
- Often follows the Demming/Shewhart cycle of Plan-Do-Check-Act
- Kaizen™ projects typically last 3 – 5 days
- Management MUST make resources available from support functions during the project. i.e., HR, Finance, Warehouse, Sales, Marketing
- Solutions are implemented based on 80% confidence instead of 95%
- Implementation is completed within the project timeline but if items fall outside, they are generally completed within 20 days
- Basic analysis is acceptable with indicative results enough to make decisions.
After the Kaizen event the following activities are recommended:
- Walkthroughs are conducted with the process area team
- Follow up with Future State process owner
- Updated Process Metrics, measure, and data
- To-Do list follow up
- The final measure of controlled metrics evaluated
- Training and SOP verification
DMAIC – a 5-step process where the 1st letter of each stage spells out DMAIC: Define, Measure, Analyze, Improve and Control. The main characteristics are:
- The existing process is not meeting customer requirements, but the reason why is not obvious
- Time is spent on analyzing the baseline data to understand current performance
- Baseline data is used to prove/validate the benefits once re-measured
- Solutions can come from anywhere and may not be popular with employees as they may mean significant changes
- Solutions require 95% confidence in being correct before implementation
- There can be a level of risk associated with the solution that will need to be accepted by the business before implementation
- Change is led by a Six Sigma Blackbelt or Greenbelt due to the nature of the data analysis.
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