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E-raamat: Lean Six Sigma Using SigmaXL and Minitab

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Barbara Lawton, Issa Bass

Formaat: 408 pages
Ilmumisaeg: 05-Jan-2009
Kirjastus: McGraw-Hill Professional
Keel: eng
ISBN-13: 9780071626217

Teised raamatud teemal:

Quality Assurance (QA) & Total Quality Management (TQM)

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Formaat: 408 pages
Ilmumisaeg: 05-Jan-2009
Kirjastus: McGraw-Hill Professional
Keel: eng
ISBN-13: 9780071626217

Teised raamatud teemal:

Quality Assurance (QA) & Total Quality Management (TQM)

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Effectively Execute Lean Six Sigma Projects using SigmaXL and Minitab

Written by a Six Sigma Master Black Belt and a Ph.D., this practical guide to Lean Six Sigma project execution follows the DMAIC (Define, Measure, Analyze, Improve, and Control) roadmap. The many real-world examples used in the book offer in-depth theoretical analyses and are implemented using the two most popular statistical software suites--SigmaXL and Minitab. This expert resource covers Lean topics ranging from basic data analysis to complex design of experiments and statistical process control. Harness the power of SigmaXL and Minitab and enable sustained positive operational results throughout your organization with help from this authoritative guide.

Lean Six Sigma Using SigmaXL and Minitab explains how to:

Define the project goals, project manager, value statement, stakeholders, and risk

Schedule tasks using the Gantt chart, critical path analysis, and program evaluation and review technique

Capture the voice of internal and external customers Assess the cost of quality Gather data and measure process performance

Perform process capabilities analysis Apply Lean Six Sigma metrics to determine baseline performance Implement analysis techniques such as Pareto analysis, value stream mapping, failure mode and effect analysis (FMEA), and regression analysis

Identify constraints via factorial experiments, and implement process improvements Monitor production performance using statistical process control

Preface

xiii

Acknowledgments

Introduction

(2)

An Overview of SigmaXL

(1)

SigmaXL menu bar

(2)

SigmaXL templates

(1)

Solution

(3)

Define

(34)

Project Planning

(6)

The Gantt chart

(3)

Program evaluation and review technique (PERT)

(2)

Project Charter

(2)

Project number

(1)

Project champion

(1)

Project definition

(1)

Project description

(1)

Value statement

(1)

Stakeholders

(1)

Project monitoring

(1)

Scheduling

(1)

Alternative plans

(1)

Risk analysis

(1)

Capturing the Voice of the Customer

(5)

Capturing the voice of the external customer

(2)

Capturing the voice of the internal customer

(1)

Capturing the voice of the customers of a project

(1)

Capturing the voice of the next step in the process

(1)

Critical-to-Quality Tree

(4)

Kano analysis

(2)

Suppliers-Input-Process-Output-Customers (SIPOC)

(3)

Cost of Quality

(5)

Assessing the cost of quality

(1)

Cost of conformance

(1)

Preventive cost

(1)

Appraisal cost

(1)

Cost of nonconformance

(1)

Internal failure

(1)

External failure

(3)

Optimal Cost of Quality

(2)

Cost of Quality According to Taguchi

(2)

Stakeholder Analysis

(5)

Force field analysis (FFA)

(4)

Measure

(100)

Data Gathering

(1)

Data Types

(1)

Attribute data

(1)

Variable data

(1)

Locational data

(1)

Basic Probability

(22)

So what is probability?

(1)

Discrete versus continuous distributions

(1)

Expected value, variance, and standard deviation of discrete distribution

(2)

Discrete probability distributions

(9)

Approximating binomial problems by Poisson distribution

(1)

Continuous distribution

(2)

Z transformation

(8)

Planning for Sampling

(1)

Random Sampling versus Nonrandom Sampling

(2)

Random sampling

(1)

Nonrandom sampling

(1)

Nonsampling errors

(1)

Sampling error

(1)

Central Limit Theorem

(13)

Sampling distribution of the mean X

(1)

Estimating the population mean with large sample sizes

(3)

Estimating the population mean with small sample sizes and σ unknown t-distribution

(3)

X2 Distribution

(3)

Estimating sample sizes

(1)

Sample size when estimating the mean

(1)

Measurement Systems Analysis

(4)

Precision and Accuracy

(14)

Measurement errors due to precision

(7)

Variations due to accuracy

(1)

Gauge bias

(2)

Gauge linearity

(4)

Attribute Gauge Study

100

(3)

Assessing a Processes Ability to Meet Customers' Expectations---Process Capability Analysis

103

(3)

Process Capabilities with Normal Data

106

(1)

Estimating Sigma

106

(1)

Short-term sigma

106

(1)

Long-term sigma

107

(1)

Potential Capabilities

107

(14)

Short-term potential capabilities, Cp and Cr

107

(2)

Long-term potential performance

109

(1)

Actual capabilities

109

(2)

Capability indices and parts per million

111

(1)

Process capability and Z transformation

111

(4)

Minitab output

115

(1)

Taguchi's capability indices CPM and PPM

116

(5)

Process Capability Analysis with Nonnormal Data

121

(1)

Normality Assumption and Box-Cox Transformation

122

(1)

Process Capability Using Box-Cox Transformation

123

(5)

Process Capability Using Nonnormal Distribution

128

(2)

Lean Six Sigma Metrics

130

(11)

Six Sigma metrics

131

(2)

First time yield (FTY)

133

(1)

Lean metrics

134

(7)

Work in Progress (WIP)

141

(2)

Analyze

143

(70)

Brainstorming

143

(1)

Nominal Group Process

143

(1)

Affinity Diagram

144

(2)

Cause-and-Effect Analysis

146

(3)

Pareto Analysis

149

(3)

Using Minitab

152

(1)

Fault Tree Analysis

152

(2)

Seven Types of Waste

154

(5)

Overproduction

156

(1)

Wait

157

(1)

Unnecessary inventory

158

(1)

Motion

158

(1)

Unnecessary transportation

158

(1)

Inappropriate processing

159

(1)

Product defects

159

(1)

Lean Approach to Waste Reduction

159

(2)

Cycle Time Reduction

161

(4)

Takt time

162

(2)

Batch versus one-piece flow

164

(1)

Data Gathering and Process Improvement

165

(3)

Value stream mapping

166

(1)

How to map your value stream

167

(1)

Failure Mode and Effect Analysis

168

(14)

Failure mode assessment

170

(1)

Action plan

171

(3)

Hypothesis testing

174

(3)

P-value method

177

(5)

Nonparametric Hypothesis Testing

182

(16)

Chi-square test

182

(3)

Contingency analysis---Chi square test of independence

185

(2)

The Mann-Whitney U test

187

(8)

Normality testing

195

(1)

Normalizing data

196

(2)

Analysis of Variance

198

(6)

Mean square

200

(4)

Regression Analysis

204

(9)

Simple linear regression (or first-order linear model)

206

(4)

Multiple regression analysis

210

(3)

Improve

213

(70)

Design of Experiments

213

(2)

Factorial Experiments

215

(19)

Main effect and interaction effect

216

(1)

2k Factorial design

217

(1)

2 2 Two factors and two levels

218

(4)

Degrees of freedom

222

(1)

Using Minitab

222

(3)

Interpretation

225

(1)

Using SigmaXL

225

(9)

Regression Model

234

(34)

SigmaXL output

236

(1)

Residual analysis

236

(1)

2k Two levels with more than 2 factors

237

(2)

Main effects for 2 3---two levels with three factors

239

(13)

Blocking

252

(2)

Confounding

254

(2)

2k-1 Fractional factorial design

256

(2)

23-1 Fractional factorial design

258

(2)

24-1 Factorial design

260

(1)

Design resolution

260

(8)

The Theory of Constraints

268

(5)

The process throughput is tied to the bottleneck

271

(2)

TOC Metrics

273

(1)

Thinking Process

273

(1)

The Goldratt Cloud

274

(1)

The Goldratt Reality Trees

275

(8)

Current reality tree

276

(2)

Future reality tree

278

(2)

280

(3)

Control

283

(50)

Statistical Process Control (SPC)

283

(12)

Variation Is the Root Cause of Defects

284

(1)

Assignable (or special) causes of variation

285

(1)

Common (or chance) causes of variation

286

(1)

How to build a control chart

287

(1)

Rational subgrouping

288

(1)

Probability for misinterpreting control charts

289

(1)

Type I error α

289

(2)

Type II error β

291

(2)

How to determine if the process is out of control---WECO rules

293

(2)

Categories of Control Charts

295

(14)

Variable control charts

295

(1)

The mean and range charts---X and R charts

296

(1)

Calculating the sample statistics to be plotted

296

(1)

Calculating the center line and control limits

297

(1)

Control limits for X chart

298

(1)

Standard-error-based X chart

298

(1)

Mean-range-based X control charts

299

(3)

Control limits for R chart

302

(3)

The mean and standard deviation charts X and s charts

305

(4)

Individual Values Control Charts

309

(1)

Individual Moving Range Charts

310

(1)

Individual Value Chart

311

(2)

Monitoring Shifts in the Process Mean

313

(4)

Cusum

314

(3)

Computational Approach

317

(2)

Exponentially Weighted Moving Average

319

(3)

Attribute Control Charts

322

(11)

The p chart

324

(3)

The np chart

327

(2)

The c chart

329

(1)

The u chart

330

(3)

Appendix. Tables

333

(14)

Table A.1 Binomial

334

(5)

Table A.2 Poisson

339

(4)

Table A.3 Chi Square

343

(1)

Table A.4 Z Table

344

(1)

Table A.5 t Table

345

(1)

Table A.6 F Table

346

(1)

Index

347

Issa Bass is a Master Black Belt and senior consultant with Manor House and Associates. He is the founding editor of SixSigmaFirst.com. Bass has extensive experience in quality and operations management, and is also the author of Six Sigma Statistics with Minitab and Excel.

Barbara Lawton, Ph.D., is a Six Sigma Black Belt, and has been improving manufacturing processes using Lean techniques and Six Sigma for more than 15 years, in various industries on 3 continents. Dr. Lawton specializes in data analysis, and is a keen experimentalist and problem solver, using a wide range of statistical tools. She currently works for one of the worlds leading aerospace organizations in the UK.

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