Six Sigma+Lean Toolset: Executing Improvement Projects Successfully

✍ Scribed by Alexander John, Renata Meran, Olin Roenpage, Christian Staudter

• Year: 2008
• Tongue: English
• Leaves: 317
• Edition: 1
• Category: Library

✦ Synopsis

The Six Sigma concept has enjoyed triumphant success throughout the business world for two decades, contributing to significant net income improvement for many companies. This successful concept has been supplemented with the tools of Lean Management, a set of strategies for improving product quality and delivery performance and reducing cost. Six Sigma+Lean links the tried-and-tested tools of both programs in the proven DMAIC process model. The chronology matches that of the approach taken in a Six Sigma+Lean improvement project.

✦ Table of Contents

Table of Contents......Page 5
Foreword......Page 9
Introduction......Page 10
– The Formula for Success......Page 12
– Quality as Success Factor......Page 14
– Acceptance as Success Factor......Page 25
– Management Commitment as Success Factor......Page 30
– Result: Measurable, Sustainable Success......Page 33
DEFINE......Page 34
– Project Charter......Page 37
– SIPOC......Page 41
– Customer Orientation......Page 43
– Research Methods for Collecting Customer Needs......Page 44
– Customer Voice Chart......Page 45
– Kano Model......Page 46
– Tool 1: CTQ Matrix......Page 49
– Tool 1: CTB Matrix......Page 51
– Stakeholder Analysis......Page 53
– Kick-Off Meeting......Page 55
– Gate Review......Page 57
– Checklist for the Define Phase......Page 59
MEASURE......Page 60
– Tool 2: Measurement Matrix......Page 63
– Data Collection Plan......Page 65
– Operational Definition......Page 67
– Data Sources and Type......Page 69
– Sampling Strategy......Page 72
– Data Collection Forms......Page 76
– Measurement System Analysis......Page 78
– Gage R & R ANOVA for Continuous Data......Page 83
– Variation......Page 86
– Graphs and Charts......Page 87
– Location and Spread Parameters......Page 102
– Process Capability Calculation......Page 109
– Checklist for the Measure Phase......Page 126
ANALYZE......Page 127
– Cause & Effect Diagram......Page 130
– FMEA......Page 132
– Process Mapping......Page 138
– Interface Analysis......Page 142
– Spaghetti Diagram......Page 144
– Value Analysis......Page 146
– Time Analysis......Page 149
– Value Stream Map......Page 151
– The Importance of Speed......Page 155
– Identifying Process Constraints......Page 158
– Tool 3: Input-Process Measurement Matrix......Page 160
– Data Stratification......Page 162
– Transforming Data......Page 164
– Hypothesis Testing......Page 167
– ANOVA......Page 174
– Correlation......Page 182
– Linear Regression......Page 184
– DOE – Design of Experiments......Page 191
– Analyze Closure Matrix......Page 206
– Checklist for the Analyze Phase......Page 207
IMPROVE......Page 208
– Theory of Constraints – TOC......Page 211
– 5 S......Page 213
– Setup Time Reduction......Page 216
– Generic Pull System......Page 219
– Replenishment Pull System......Page 222
– Poka Yoke......Page 227
– Total Productive Maintenance – TPM......Page 230
– Lean for Service......Page 234
– Creativity Techniques......Page 237
– Tools for Selecting Solutions......Page 246
– Implementation Planning......Page 257
– Pilot Program......Page 267
– Roll Out......Page 269
– Checklist for the Improve Phase......Page 270
CONTROL......Page 271
– Process Documentation......Page 274
– Monitoring / Visual Process Monitoring and Control......Page 276
– Monitoring / Control Charts......Page 278
– Reaction Plan......Page 287
– Checklist for the Control Phase......Page 289
Project Documentation......Page 290
Project Closure......Page 292
Kaizen DMAIC......Page 293
– Abbreviations......Page 296
B......Page 299
C......Page 300
D......Page 302
F......Page 304
I......Page 305
L......Page 306
M......Page 307
O......Page 308
P......Page 309
R......Page 311
S......Page 312
T......Page 314
W......Page 315
Y......Page 316
– Sigma Value Table......Page 317