Reliability improves fastest when teams pair DMAIC for problem‑solving discipline with RCA for true cause removal. This guide shows how to define, measure, analyze, improve, and control—while turning findings into standard work that sticks.
See how Strategy Optimizer™ deploys RCA‑derived tasks to like assets
What is DMAIC RCA?
DMAIC, pronounced “duh-may-ik," is a data-driven approach to problem-solving designed to identify and improve existing process inefficiencies with unknown causes.
As one of the most important tools in any continuous improvement toolbox, this five-phase strategy - Define, Measure, Analyze, Improve and Control (DMAIC) - acts as the foundation for any process improvement project. Most often associated with Six Sigma or Lean methodologies, DMAIC is also used by those who don’t subscribe to any methodology but rather share a common goal of improving operations and becoming more efficient.
With proper implementation, the DMAIC process provides an effective problem-solving framework to standardize root cause thinking, reduce variability, and ensure world-class Root Cause Analysis (RCA) results.
DMAIC RCA Flow for Reliability:
Define (problem, scope, value):
Define the problem against various areas affected such as; HSE, Reliability, Quality, Production, Vehicle, etc. Get to grips with exactly what the current state is and what the intended improvement outcomes should be.
- Identify opportunities with high potential for improvement
- Estimate the impact the project will have
- Provide an overview of an entire process
- Record incident details
- Define data collection and measurement requirements for evidence
Measure (baseline, data quality):
Measure the process so you can see what the impact of the problem is. Define what you’re going to measure, so you can understand the problem in greater detail. Map the process to determine the exact events leading up to the incident and start sorting through the details to collect and organize the data for analysis.
- Identify input, processes, and output indicators
- Outline the Failure Modes and Effects Analysis (FMEA)
- Gather, collect, and examine evidence with current state data (asset health readings, maintenance records, photos, interviews, personal accounts, etc.)
- Establish the baseline process "as is" and define the goals of the investigation
Analyze (RCA methods):
Analyze the process to understand the root cause(s) and the reasons for defects. Investigate the data collected from the measure phase into fact-driven evidence to determine potential causes. Visually display and identify the root cause through RCA tools and suggest corrective actions.
- Complete a root cause analysis (Five Whys, Fishbone/Ishikawa, Cause Map)
- Determine an incident’s risk using a Risk Matrix and review any mitigations against its Failure Mode libraries
- Complete an FMEA for identifying possible equipment, service, and process failures
- Develop an improvement plan with recommended actions to eliminate or mitigate the effect of the problem
Improve (make it tangible):
Improve the process by eliminating the root causes. Analyze and validate the suggested actions from the Analyze phase and develop an implementation plan to gain approval and ensure effective change management.
- Gather potential solutions or generate new ones with facts uncovered from the analysis
- Weigh each solution to determine viability and effectiveness using process maps or PDAC methods
- Outline a pilot/test solution and implementation plan
- Make a final decision and implement the solution
Control (make it stick):
Control future performance of the process by standardizing the new way of working. Track the implementation and effects to prove the recurring problem has been eliminated or indicate further actions/analysis is needed. Create an A3 report to identify performance trends and share learnings.
- Create a Monitoring Plan to track implementations and verify failure reductions
- Develop and initiate a Response Plan if improvements start to decline
- Document the new work standard
- Integrate and communicate the lessons learned with A3 Reporting
- Continuously improve the process
Summing It All Up
DMAIC can be quick and easy for simple problems with clear root causes, or it can involve many improvement tools and cross-functional collaboration for more difficult challenges. In either case, it requires discipline and attention to detail, two very important elements of continuous improvement.
The simple, yet highly structured DMAIC process provides organizations with a well-defined and consistent approach to problem-solving that supports productivity, collaboration, and a reliability-focused culture.
Example: From Recurring Failure to Sustained FixRecurring pump seal failures → sustained fix
Metrics That Matter (Leading → Lagging)
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Leading: plan coverage for updated job plans; kit completeness; closeout completeness (% time/parts/failure/cause); audit pass rate; action item aging.
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Lagging: MTBF/MTTR, unplanned downtime, rework %, maintenance cost/asset.
Common Pitfalls (and Fixes)
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Treating RCA as a meeting, not a method → Use structured tools and assign facilitators.
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Great analysis, no translation → Write standard work (job plans/PMs) with parts & tools.
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One‑and‑done improvements → Control plan with audits and KPI triggers.
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Dirty data → Mandatory closeout fields + weekly completeness review.
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Over‑engineering all problems → Triage: quick 5 Whys for low risk; FMECA/design change for high risk.
What's Next?
Now that you have a clear picture of a DMAIC RCA process. Let's talk about adopting DMAIC RCA within your organization.
As new technologies continually make their way into the business landscape, the race to the bottom line is more competitive than ever. As such, more and more organizations are turning to DMAIC using improvement technologies to gain and maintain a competitive edge.
With efficiency at its core, implementing a DMAIC strategy should never be costly, timely, or challenging. Investigation Optimizer™ guides you through each step of a Lean Six Sigma DMAIC process as a simple, reliable RCA and continuous improvement software. Entire organizations can collaborate with ease and share lessons learned to quickly and confidently solve problems, reduce risk, and continuously improve performance.
FAQ
What’s the difference between DMAIC and RCA?
DMAIC is the improvement framework; RCA is the engine of Analyze that finds true causes and effective countermeasures.
When should we escalate to FMEA/FMECA?
When risk is high (safety, environment, major downtime) or recurrence persists despite fixes.
How do we make improvements stick?
Translate findings into job plans, PMs, and design changes; add a control plan with audits, KPIs, and a change log.
What data is essential?
Closeout time, parts, failure, cause, and notes/photos—audited weekly for completeness.
Topics: Article, Investigation Management
Posted by
Larry Olson | CMRP, CRL, CAMA
CEO, Nexus Global | Larry is one of the leading global Shutdown/Turnaround, Asset Integrity, and Maintenance strategists. With over 30+ years of business & maintenance experience, he has carried out a variety of roles from Project Manager, Change Management Specialist to Director of Reliability & Integrity Assurance Excellence.
