Define tollgate and garment project exercise

Learning objectives

• Confirm Define deliverables are complete and consistent.
• Defend the project logic in front of a sponsor.
• Identify readiness gaps before Measure begins.

Scenario used for this tollgate

A knit factory faces buyer complaints about measurement inconsistency, rising final-inspection failures, growing repair volume and shipment risk across three similar styles.

Required outputs to defend

• Evidence-based problem and SMART goal.
• Customer/VOC summary and CTQs.
• Scope, charter and stakeholder plan.
• Benefit hypothesis, SIPOC and high-level current-state map.
• The specific Measure-phase questions.

Gate questions the sponsor will ask

• Is the defect operationally clear?
• Does scope match authority and available time?
• Is the baseline source credible enough to proceed?
• Are sponsor, process owner, resources and guardrails confirmed?

Garment-factory example

Presenting root causes as facts at this gate is a red flag — Define has not tested causes yet, and doing so tells the sponsor the belt does not know where they are in DMAIC.

Method

1. Assemble every mandatory Define deliverable.
2. Resolve contradictions between charter, VOC and SIPOC.
3. Label assumptions clearly.
4. Obtain and record sponsor and process-owner approval.

Common mistakes

• Presenting suspected causes as proven facts.
• Approving a project without a reliable measurement plan.