CONTENTS. Preface...xiii. Six Sigma Implementation and Management

Transcription

1 CONTENTS Preface...xiii PART I Six Sigma Implementation and Management CHAPTER 1 Building the Responsive Six Sigma Organization... 3 What Is Six Sigma?... 3 Why Six Sigma? The Six Sigma Philosophy... 6 Six Sigma Versus Traditional Three Sigma Performance The Change Imperative Implementing Six Sigma Timetable Infrastructure Integrating Six Sigma and Related Initiatives Deployment to the Supply Chain Communications and Awareness CHAPTER 2 Recognizing and Capitalizing on Opportunity Methods for Collecting Customer Data Surveys Focus Groups Operational Feedback Systems Cost of Poor Quality Cost of Quality Examples Quality Cost Bases Benchmarking The Benchmarking Process Getting Started with Benchmarking Why Benchmarking Efforts Fail The Benefits of Benchmarking v 00_FM.indd 5

2 vi Contents Some Dangers of Benchmarking Innovation Kano Model Quality Function Deployment Translating Customer Demands Creative Destruction Strategic Planning Organizational Vision Strategy Development Strategic Styles Possibilities-Based Strategic Decisions Strategic Development Using Constraint Theory The Systems Approach Basic Constraint Management Principles and Concepts Tools of Constraint Management Constraint Management Measurements Summary and Conclusion CHAPTER 3 Data-Driven Management Attributes of Good Metrics Measuring Causes and Effects The Balanced Scorecard Translating the Vision Communicating and Linking Business Planning Feedback and Learning CHAPTER 4 Maximizing Resources Choosing the Right Projects Types of Projects Analyzing Project Candidates Using Pareto Analysis to Identify Six Sigma Project Candidates. 187 Throughput-Based Project Selection Ongoing Management Support Internal Roadblocks External Roadblocks Individual Barriers to Change _FM.indd 6

3 Contents vii Ineffective Management Support Strategies Effective Management Support Strategies Cross-Functional Collaboration Tracking Six Sigma Project Results Financial Results Validation Team Performance Evaluation Team Recognition and Reward Lessons-Learned Capture and Replication PART II Six Sigma Tools and Techniques CHAPTER 5 Project Management Using DMAIC and DMADV DMAIC and DMADV Deployment Models Project Scheduling Project Reporting Project Budgets Project Records Six Sigma Teams Team Membership Team Dynamics Management, Including Conflict Resolution Stages in Group Development Member Roles and Responsibilities Management s Role Facilitation Techniques CHAPTER 6 The Define Phase Project Charters Project Decomposition Work Breakdown Structures Pareto Analysis Deliverables Critical to Quality Metrics Critical to Schedule Metrics Critical to Cost Metrics Top-Level Process Definition Process Maps Assembling the Team _FM.indd 7

4 viii Contents CHAPTER 7 The Measure Phase Process Definition Flowcharts SIPOC Metric Definition Measurement Scales Discrete and Continuous Data Process Baseline Estimates Enumerative and Analytic Studies Principles of Statistical Process Control Estimating Process Baselines Using Process Capability Analysis CHAPTER 8 Process Behavior Charts Distributions Methods of Enumeration Frequency and Cumulative Distributions Sampling Distributions Binomial Distribution Poisson Distribution Hypergeometric Distribution Normal Distribution Lognormal Distribution Exponential Distribution Weibull Distribution Control Charts for Variables Data Averages and Ranges Control Charts Averages and Standard Deviation (Sigma) Control Charts Control Charts for Individual Measurements (X Charts) Control Charts for Attributes Data Control Charts for Proportion (p Charts) Control Charts for Count of Items (np Charts) Control Charts for Average Occurrences-Per-Unit (u Charts) Control Charts for Counts of Occurrences-Per-Unit (c Charts) Control Chart Selection Rational Subgroup Sampling Control Chart Interpretation Run Tests _FM.indd 8

5 Contents ix Short-Run Statistical Process Control Techniques Variables Data Attribute SPC for Small and Short Runs Summary of Short-Run SPC SPC Techniques for Automated Manufacturing Problems with Traditional SPC Techniques Special and Common Cause Charts EWMA Common Cause Charts EWMA Control Charts Versus Individuals Charts Process Capability Indices Example of Non-Normal Capability Analysis Using Minitab CHAPTER 9 Measurement Systems Evaluation Definitions Measurement System Discrimination Stability Bias Repeatability Reproducibility Part-to-Part Variation Summary Reporting Gage R&R Analysis Using Minitab Linearity Linearity Analysis Using Minitab Attribute Measurement Error Analysis Operational Definitions How to Conduct Attribute Inspection Studies Minitab Attribute Gage R&R Example CHAPTER 10 Analyze Phase Value Stream Analysis Value Stream Mapping Spaghetti Charts Analyzing the Sources of Variation Cause and Effect Diagrams Boxplots Statistical Inference _FM.indd 9

6 x Contents Chi-Square, Student s t, and f Distributions Point and Interval Estimation Hypothesis Testing Resampling (Bootstrapping) Regression and Correlation Analysis Linear Models Least-Squares Fit Correlation Analysis Designed Experiments The Traditional Approach Versus Statistically Designed Experiments Terminology Design Characteristics Types of Design One-Factor ANOVA Two-Way ANOVA with No Replicates Two-Way ANOVA with Replicates Full and Fractional Factorial Power and Sample Size Testing Common Assumptions Analysis of Categorical Data Making Comparisons Using Chi-Square Tests Logistic Regression Binary Logistic Regression Ordinal Logistic Regression Nominal Logistic Regression Non-Parametric Methods CHAPTER 11 The Improve/Design Phase Using Customer Demands to Make Design and Improvement Decisions Pugh Concept Selection Method Lean Techniques for Optimizing Flow Unnecessary Process Steps Excessive Movement of Material or Personnel Bottleneck or Constraint Process Errors Requiring Rework Excess In-process Inventory _FM.indd 10

7 Contents xi Understanding Queues to Balance Processes Using Empirical Model Building to Optimize Phase 0: Getting Your Bearings Phase I: The Screening Experiment Phase II: Steepest Ascent (Descent) Phase III: The Factorial Experiment Phase IV: The Composite Design Phase V: Robust Product and Process Design Data Mining, Artificial Neural Networks, and Virtual Process Mapping Example of Neural Net Models Optimization Using Simulation Predicting CTQ Performance Simulation Tools Random Number Generators Model Development Virtual DOE Using Simulation Software Risk Assessment Tools Design Review Fault-Tree Analysis Safety Analysis Failure Mode and Effect Analysis Defining New Performance Standards Using Statistical Tolerancing. 581 Assumptions of Formula Tolerance Intervals CHAPTER 12 Control/Verify Phase Validating the New Process or Product Design Business Process Control Planning Maintaining Gains Tools and Techniques Useful for Control Planning Preparing the Process Control Plan Process Control Planning for Short and Small Runs Process Audits Selecting Process Control Elements Other Elements of the Process Control Plan Multivariate Control Charts Principal Component Analysis _FM.indd 11

8 xii Contents APPENDIX 1 Glossary of Basic Statistical Terms APPENDIX 2 Area Under the Standard Normal Curve APPENDIX 3 Critical Values of the t-distribution APPENDIX 4 Chi-Square Distribution APPENDIX 5 F Distribution (a = 1%) APPENDIX 6 F Distribution (a = 5%) APPENDIX 7 Poisson Probability Sums APPENDIX 8 Tolerance Interval Factors APPENDIX 9 Control Chart Constants APPENDIX 10 Control Chart Equations APPENDIX 11 Table of d 2 * Values APPENDIX 12 Factors for Short Run Control Charts for Individuals, X, and R Charts APPENDIX 13 Sample Customer Survey APPENDIX 14 Process s Levels and Equivalent PPM Quality Levels APPENDIX 15 Black Belt Effectiveness Certification APPENDIX 16 Green Belt Effectiveness Certification APPENDIX 17 AHP Using Microsoft Excel Notes References Index _FM.indd 12