Walk a Defect Escape Through DMAIC
Choose first-hour actions after a defect escape that contain risk while preserving DMAIC evidence.
Customer-visible escape A customer reports a missing safety insert. Forty-two similar kits are packed, nine are shipped, and the afternoon batch starts in 35 minutes. The wrong first move either lets more defects escape or wipes out the evidence needed for RCA. Contain -> Preserve -> Temporarily Control The first-hour DMAIC compression Use DMAIC under pressure: define the suspect population, measure exposure, preserve evidence, install a temporary gate, and only then move into full root-cause analysis. Reflex Stop everything and tell people to be careful. Customers are protected while the later RCA stays evidence-based. Containment buys time; evidence makes prevention…
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