List of Figures and Tables |
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xvi | |
Preface |
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xxii | |
Acknowledgments |
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xxv | |
Part I Overview: Six Sigma and the Organization |
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1 | (72) |
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Chapter 1 Six Sigma and Organizational Goals |
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2 | (29) |
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2 | (23) |
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Why Use Six Sigma versus Other Methodologies? |
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2 | (1) |
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How Six Sigma Philosophy and Goals Should Be Applied |
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3 | (1) |
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The Lead-Up to the Six Sigma Methodology |
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4 | (2) |
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6 | (2) |
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8 | (7) |
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15 | (1) |
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16 | (1) |
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Process Inputs, Outputs, and Feedback |
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16 | (2) |
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Significance of Six Sigma |
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18 | (1) |
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19 | (1) |
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20 | (1) |
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21 | (2) |
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23 | (1) |
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Cost-Benefit Analysis: (Cost of Quality, Quality Cost, Cost of Poor Quality, Cost of Current Quality) |
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23 | (2) |
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2 Organizational Goals and Six Sigma Projects |
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25 | (3) |
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Linking Projects to Organizational Goals |
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25 | (3) |
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3 Organizational Drivers and Metrics |
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28 | (3) |
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28 | (1) |
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Voice of the Customer (VOC) |
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28 | (1) |
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29 | (1) |
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29 | (1) |
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Key Performance/Process Indicator (KPI) |
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30 | (1) |
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Chapter 2 Lean Principles in the Organization |
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31 | (18) |
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31 | (13) |
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32 | (2) |
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Some of the Top Lean Tools |
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34 | (7) |
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41 | (3) |
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Additional Forms of Waste |
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44 | (1) |
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44 | (5) |
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44 | (5) |
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Chapter 3 Design for Six Sigma (DFSS) Methodologies |
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49 | (24) |
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49 | (5) |
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50 | (1) |
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51 | (3) |
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2 Basic Failure Mode and Effects Analysis (FMEA) |
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54 | (15) |
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56 | (2) |
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58 | (1) |
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58 | (3) |
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Severity, Occurrence, and Detection Tables |
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61 | (3) |
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64 | (2) |
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66 | (1) |
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67 | (2) |
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3 Design FMEA and Process FMEA |
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69 | (7) |
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Differences between Design and Process FMEA |
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72 | (1) |
Part II Define Phase |
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73 | (80) |
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74 | (2) |
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Chapter 4 Project Identification |
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76 | (9) |
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76 | (1) |
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77 | (1) |
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78 | (1) |
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4 Process Inputs and Outputs |
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79 | (4) |
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83 | (1) |
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5 Owners and Stakeholders |
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83 | (2) |
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Chapter 5 Voice of the Customer (VOC) |
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85 | (10) |
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1 Customer Identification |
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85 | (1) |
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86 | (1) |
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87 | (8) |
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90 | (5) |
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Chapter 6 Project Management Basics |
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95 | (7) |
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95 | (1) |
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96 | (1) |
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96 | (1) |
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97 | (1) |
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97 | (1) |
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98 | (1) |
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99 | (2) |
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101 | (1) |
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Chapter 7 Management and Planning Tools |
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102 | (24) |
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102 | (1) |
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Advanced Quality Planning |
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103 | (1) |
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103 | (1) |
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104 | (2) |
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106 | (1) |
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107 | (1) |
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Cause-and-Effect Diagram (Fishbone, Ishikawa Diagram) |
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107 | (1) |
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108 | (1) |
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109 | (1) |
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Failure Mode and Effects Analysis (FMEA) |
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109 | (1) |
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109 | (1) |
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110 | (2) |
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112 | (1) |
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112 | (1) |
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Graphical Charts, Control Charts, and other Statistical Tools |
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113 | (2) |
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113 | (1) |
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114 | (1) |
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Charts for Other Kinds of Data |
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114 | (1) |
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Interrelationship Diagram (Digraph) |
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115 | (1) |
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115 | (1) |
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115 | (1) |
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116 | (1) |
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116 | (1) |
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117 | (2) |
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119 | (1) |
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119 | (2) |
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Process Decision Program Chart |
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121 | (1) |
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Project Evaluation and Review Technique (PERT) |
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121 | (1) |
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Quality Function Deployment |
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121 | (1) |
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122 | (1) |
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122 | (1) |
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Suppliers-Inputs-Process-Outputs-Customers (SIPOC) Diagram |
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123 | (1) |
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123 | (2) |
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125 | (1) |
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125 | (1) |
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Chapter 8 Business Results for Projects |
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126 | (5) |
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127 | (2) |
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129 | (2) |
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Chapter 9 Team Dynamics and Performance |
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131 | (22) |
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131 | (1) |
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131 | (1) |
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132 | (1) |
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1 Team Stages and Dynamics |
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132 | (7) |
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133 | (1) |
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133 | (1) |
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133 | (1) |
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134 | (1) |
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Stage 5: Transitioning/Adjourning |
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134 | (1) |
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134 | (1) |
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134 | (1) |
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135 | (4) |
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2 Team Roles and Responsibilities |
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139 | (6) |
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145 | (7) |
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145 | (5) |
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150 | (1) |
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150 | (2) |
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152 | (1) |
Part III Measure Phase |
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153 | (100) |
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Chapter 10 Process Analysis and Documentation |
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154 | (14) |
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Process Maps and Flowcharts |
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154 | (5) |
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Written Procedures and Work Instructions |
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158 | (1) |
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Process Inputs and Outputs |
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159 | (9) |
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166 | (2) |
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Chapter 11 Probability and Statistics |
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168 | (11) |
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1 Basic Probability Concepts |
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168 | (6) |
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Simple Events Probability |
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168 | (1) |
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Compound Events Probability |
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169 | (1) |
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169 | (2) |
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Mutually Exclusive Events |
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171 | (1) |
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171 | (1) |
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Permutations and Combinations |
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172 | (2) |
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174 | (5) |
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Definition and Description |
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174 | (2) |
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Use of Central Limit Theorem in Control Charts |
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176 | (1) |
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Use of Central Limit Theorem in Hypothesis Testing |
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176 | (1) |
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Drawing Valid Statistical Conclusions |
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177 | (2) |
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Chapter 12 Statistical Distributions |
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179 | (13) |
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179 | (3) |
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Normal Approximations of the Binomial |
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182 | (1) |
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182 | (3) |
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185 | (2) |
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187 | (1) |
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188 | (1) |
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189 | (1) |
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190 | (2) |
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Chapter 13 Collecting and Summarizing Data |
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192 | (25) |
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1 Types of Data and Measurement Scales |
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192 | (1) |
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2 Sampling and Data Collection Methods |
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193 | (4) |
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Techniques for Assuring Data Accuracy and Integrity |
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194 | (2) |
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195 | (1) |
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196 | (1) |
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197 | (4) |
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Cumulative Frequency Distribution |
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200 | (1) |
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201 | (36) |
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203 | (1) |
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204 | (3) |
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207 | (1) |
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208 | (6) |
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214 | (1) |
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215 | (2) |
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Chapter 14 Measurement System Analysis |
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217 | (20) |
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Chapter 15 Process and Performance Capability |
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237 | (16) |
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1 Process Performance vs. Process Specifications |
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237 | (4) |
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Test Results for X Chart of Length |
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239 | (1) |
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Test Results for R Chart of Length |
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239 | (2) |
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2 Process Capability Studies |
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241 | (4) |
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Steps for Process Capability Studies |
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242 | (2) |
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Sampling with Respect to Statistical Process Control |
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244 | (1) |
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3 Process Capability (Cp, Cpk) and Process Performance (Pp, Ppk) Indices |
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245 | (2) |
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Process Capability Calculations |
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246 | (1) |
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4 Short-Term vs. Long-Term Capability and Sigma Shift |
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247 | (7) |
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Short-Term vs. Long-Term Capability |
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249 | (4) |
Part IV Analyze Phase |
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253 | (60) |
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253 | (1) |
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Chapter 16 Exploratory Data Analysis |
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254 | (25) |
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254 | (9) |
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Procedure for Multi-Vari Sampling Plan |
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255 | (8) |
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2 Correlation and Linear Regression |
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263 | (16) |
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263 | (1) |
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Correlation versus Causation |
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263 | (1) |
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264 | (6) |
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270 | (4) |
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Confidence Interval for the Regression Line |
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274 | (2) |
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Multiple Linear Regression |
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276 | (3) |
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Chapter 17 Hypothesis Testing |
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279 | (34) |
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279 | (6) |
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The Null and Alternative Hypotheses |
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279 | (1) |
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280 | (1) |
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280 | (2) |
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282 | (1) |
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283 | (1) |
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Statistical and Practical Significance |
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283 | (1) |
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284 | (1) |
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When to Calculate Statistically Significant Sample Size |
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284 | (1) |
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How to Calculate Statistically Significant Sample Size |
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284 | (1) |
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285 | (1) |
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2 Tests for Means, Variances, and Proportions |
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285 | (29) |
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286 | (1) |
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Hypothesis Tests for Means |
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286 | (2) |
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288 | (2) |
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Confidence Intervals for the Mean |
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290 | (1) |
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291 | (1) |
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Confidence Intervals for Variation |
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292 | (1) |
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293 | (1) |
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Confidence Intervals for Proportion |
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293 | (1) |
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One Population Proportion (p-Test) |
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294 | (2) |
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296 | (5) |
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Two-Mean, Equal Variance t-Test |
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296 | (1) |
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Two-Mean, Unequal Variance t-Test |
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297 | (1) |
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298 | (2) |
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300 | (1) |
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Single-Factor Analysis of Variance (ANOVA) |
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301 | (7) |
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301 | (7) |
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308 | (6) |
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Procedure for Chi-Square Test |
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308 | (3) |
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311 | (1) |
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Parametric and Nonparametric Tests |
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312 | (1) |
Part V Improve Phase |
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313 | (60) |
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Chapter 18 Design of Experiments (DOE) |
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314 | (24) |
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314 | (9) |
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314 | (1) |
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314 | (1) |
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314 | (1) |
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315 | (1) |
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315 | (1) |
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315 | (1) |
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315 | (1) |
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315 | (1) |
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315 | (1) |
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315 | (1) |
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316 | (1) |
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316 | (1) |
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DOE Overview-Planning and Organizing Experiments |
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316 | (7) |
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323 | (15) |
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323 | (2) |
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325 | (2) |
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327 | (1) |
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327 | (1) |
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Design and Analysis of One-Factor Experiments |
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328 | (2) |
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Design and Analysis of Full Factorial Experiments |
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330 | (3) |
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Design and Analysis of Two-Level Fractional Factorial Experiments |
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333 | (1) |
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Two-Level Fractional Factorial Experiment Procedure |
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334 | (2) |
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Two-Level Fractional Factorial Experiment Conclusions |
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336 | (1) |
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Testing Main Effects and Interactions |
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337 | (1) |
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Design of Experiments Considerations |
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337 | (1) |
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Chapter 19 Root Cause Analysis |
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338 | (11) |
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Phase 1: Identify the Opportunity (Problem Identification) |
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339 | (1) |
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Phase 2: Analyze the Current Process |
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340 | (1) |
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Phase 3: Develop the Optimal Solution(s) (Correction) |
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341 | (1) |
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Phase 4: Implement Changes |
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341 | (1) |
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Phase 5: Study the Results |
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341 | (1) |
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Phase 6: Standardize the Solution (Recurrence Control) |
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341 | (1) |
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Phase 7: Plan for the Future (Effectiveness Assessment) |
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342 | (1) |
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342 | (1) |
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Root Cause Analysis Methodology |
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342 | (1) |
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343 | (6) |
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Cause-and-Effect Diagram (Fishbone Diagram) |
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343 | (2) |
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345 | (1) |
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Is/Is Not Comparative Analysis |
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345 | (1) |
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Cause-and-Effect (X-Y) Relational Matrix |
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346 | (1) |
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346 | (2) |
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Failure Mode and Effects Analysis |
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348 | (1) |
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349 | (24) |
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349 | (7) |
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Relevance of Lean to Six Sigma |
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349 | (1) |
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Comparison of Lean to Traditional Systems |
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350 | (1) |
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351 | (5) |
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352 | (1) |
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Mistake-Proofing (Error-Proofing or Poka-Yoke) |
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353 | (1) |
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354 | (1) |
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354 | (1) |
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354 | (1) |
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355 | (1) |
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Total Productive Maintenance |
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355 | (1) |
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355 | (1) |
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356 | (10) |
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356 | (2) |
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358 | (1) |
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358 | (1) |
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358 | (1) |
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359 | (1) |
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359 | (1) |
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360 | (1) |
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360 | (3) |
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Countermeasure Activities |
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363 | (1) |
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Quick Changeover/Setup Reduction |
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364 | (1) |
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Cycle Time Reduction Through Constraints Management |
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365 | (1) |
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3 Kaizen and Kaizen Blitz |
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366 | (8) |
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Incremental Continuous Improvement (Kaizen) |
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366 | (1) |
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366 | (1) |
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Breakthrough Continuous Improvement (Kaikaku) |
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367 | (7) |
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369 | (1) |
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369 | (4) |
Part VI Control Phase |
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373 | (66) |
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Chapter 21 Statistical Process Control (SPC) |
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374 | (39) |
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374 | (11) |
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Statistical Process Control |
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374 | (1) |
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375 | (1) |
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376 | (1) |
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Process Capability: Special versus Common Causes |
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377 | (1) |
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Process Data: Discrete versus Continuous |
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378 | (2) |
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Discrete Data (Attributes Control Charts) |
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380 | (1) |
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Continuous Data (Variables Control Charts) |
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380 | (1) |
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Process Behavior Charts (Control Charts) |
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380 | (5) |
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385 | (3) |
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Rational Subgrouping Method |
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386 | (1) |
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Rational Subgrouping Approach |
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387 | (1) |
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388 | (25) |
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Selection and Application of Control Charts |
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388 | (1) |
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388 | (1) |
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389 | (1) |
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389 | (3) |
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392 | (2) |
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Individuals and Moving Range Control Charts |
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394 | (1) |
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395 | (1) |
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Attributes Control Charts |
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395 | (2) |
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397 | (2) |
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399 | (2) |
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401 | (1) |
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402 | (2) |
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Analysis of Control Charts |
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404 | (9) |
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413 | (11) |
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Examples of Process Controls |
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418 | (1) |
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418 | (2) |
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420 | (1) |
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Standard Operating Procedures |
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420 | (1) |
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421 | (1) |
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422 | (2) |
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Chapter 23 Lean Tools for Process Control |
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424 | (15) |
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1 Total Productive Maintenance (TPM) |
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424 | (7) |
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427 | (2) |
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Overall Equipment Effectiveness (OEE) |
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429 | (2) |
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431 | (8) |
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431 | (1) |
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432 | (7) |
Part VII Appendices |
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439 | (116) |
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Appendix A ASQ Code of Ethics |
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440 | (2) |
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Appendix B The ASQ Certification Process |
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442 | (9) |
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Appendix C Six Sigma Green Belt Body of Knowledge Map 2006-2014 |
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451 | (7) |
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Appendix D ASQ Certified Six Sigma Green Belt (CSSGB) Body of Knowledge (2014) |
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458 | (8) |
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Appendix E ASQ Certified Six Sigma Yellow Belt (CSSYB) Body of Knowledge (2014) |
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466 | (5) |
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Appendix F ASQ Certified Six Sigma Black Belt (CSSBB) Body of Knowledge (2015) |
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471 | (11) |
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Appendix G ASQ Certified Six Sigma Master Black Belt (CSSMBB) Body of Knowledge (2010) |
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482 | (10) |
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Appendix H ASQ Honorary Members |
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492 | (2) |
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Appendix I Control Limit Formulas |
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494 | (1) |
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Appendix J Constants for Control Charts |
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495 | (1) |
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Appendix K Areas under Standard Normal Curve |
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496 | (4) |
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Appendix L F Distributions |
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500 | (10) |
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Appendix M Binomial Distribution |
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510 | (2) |
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Appendix N Chi-Square Distribution |
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512 | (2) |
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Appendix O Exponential Distribution |
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514 | (2) |
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Appendix P Poisson Distribution |
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516 | (2) |
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Appendix Q Values of the t-Distribution |
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518 | (2) |
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Appendix R CSSGB Handbook CD-ROM |
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520 | (2) |
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522 | (30) |
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Appendix T Quality Gamebox |
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552 | (3) |
Endnotes |
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555 | (4) |
Glossary |
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559 | (28) |
References |
|
587 | |