Inventory. Revenue. Vendors. Supply chain. Cash flow. Cross-system failures are hiding across all of it. Sign up β your critical intelligence tabs are waiting.
The structured five-phase approach to process improvement. Each phase has defined inputs, tools, and deliverables.
Establish the project scope, business case, and customer requirements. Identify the problem, form the team, and create the project charter.
Key Questions
Phase Deliverables
Tools & Techniques
Eliminate waste, improve flow, and create value. These tools complement Six Sigma for a comprehensive improvement approach.
Visualize end-to-end material and information flows to identify waste and improvement opportunities.
Sort, Set in Order, Shine, Standardize, Sustain β foundation for operational excellence.
Rapid 3-5 day improvement workshops targeting specific process bottlenecks.
Pull-based production control limiting work-in-progress and improving flow.
Reduce setup and changeover times to enable smaller batch sizes and flexibility.
Proactive equipment maintenance maximizing OEE and eliminating unplanned downtime.
Documented best-practice sequences establishing consistent, repeatable processes.
Design mechanisms that prevent defects from occurring or detect them immediately.
Monitor and control process performance using statistical methods. Our AI automatically calculates these metrics from your uploaded data.
Measures how well a process fits within specification limits. Cpk >= 1.33 is capable; >= 1.67 is excellent.
Long-term process performance including all sources of variation. Compares to Cpk for stability assessment.
Number of standard deviations between process mean and nearest spec limit. 6-Sigma = 3.4 DPMO.
Defects Per Million Opportunities β universal quality metric across industries.
Percentage of units that pass through a process step without rework or scrap.
Overall Equipment Effectiveness = Availability x Performance x Quality. World-class: 85%+.
Upload your process data to the Data Hub and our AI will automatically calculate Cpk/Ppk, sigma levels, DPMO, and generate control charts. The system identifies out-of-control patterns (Western Electric rules) and recommends corrective actions using DMAIC methodology.
Upload Process DataLean Six Sigma principles are universal. Our platform adapts methodologies and benchmarks to your specific industry context.
Systematically identify potential failures, assess their severity, occurrence, and detection capability to calculate Risk Priority Numbers (RPN) and prioritize corrective actions.
Scientifically determine the optimal process settings by systematically varying input factors and measuring their effects on outputs.
Structured problem-solving techniques to identify the fundamental cause of issues rather than treating symptoms.
Live-updating calculations β slide inputs to size improvement potential instantly. No backend, no sign-up required.
Quantify process quality per million opportunities.
Target: β₯ 4.0Ο (6,210 DPMO). World-class: 6Ο (3.4 DPMO).
Overall Equipment Effectiveness = A Γ P Γ Q
Risk Priority Number = Severity Γ Occurrence Γ Detection
Cpk = min(USL β ΞΌ, ΞΌ β LSL) / 3Ο
Describe your problem. DuluthPath AI generates a full DMAIC roadmap β project charter, CTQ tree, phase-by-phase activities, sigma lift, and $ impact.
Opus 4 Enterprise / Platinum β 4,000 token full roadmap.
Sonnet Guest / Pilot β 2,000 token summary with upsell.
Compare your current performance to peer and best-in-class benchmarks across 8 core process metrics.
| Metric | Poor | Average | Good | World-Class |
|---|---|---|---|---|
| Sigma Level | < 2.5Ο | 3.0Ο | 4.0Ο | β₯ 6.0Ο |
| DPMO | > 100,000 | 66,800 | 6,210 | β€ 3.4 |
| First Pass Yield | < 80% | 85% | 95% | β₯ 99% |
| OEE (Manufacturing) | < 40% | 60% | 75% | β₯ 85% |
| Cpk | < 1.0 | 1.0 | 1.33 | β₯ 1.67 |
| On-Time Delivery | < 85% | 92% | 97% | β₯ 99.5% |
| O2C Cycle (days) | > 60 | 40 | 25 | β€ 18 |
| Customer Complaints (ppm) | > 10,000 | 5,000 | 1,000 | β€ 100 |
Project charter, SIPOC, FMEA, control plan, and more. Free tier unlocks the starter pack. Enterprise unlocks the full library.
DMAIC project initialization form
Supplier-Input-Process-Output-Customer map
6M root-cause brainstorming template
Root cause drill-down worksheet