The Six Sigma Handbook, Revised and Expanded

by Pyzdek, Thomas

• ISBN13: 9780071410151
• ISBN10: 0071410155
• Edition: 2nd
• Format: Hardcover
• Copyright: 2003-03-20
• Publisher: McGraw-Hill

Summary

The management information and statistical tools you need to successfully implement Six SigmaSix Sigma has helped organizations of all types and sizes improve the quality of processes and products while simultaneously increasing customer satisfaction and saving billions of dollars. "The Six Sigma Handbook covers the management systems and statistical tools that are the foundation for this revolutionary new approach to management.Thomas Pyzdek offers expert, proven advice on using Six Sigma to retain customers and enhance bottom line performance while cutting costs dramatically. He explains exactly how to make Six Sigma work, including organizing for Six Sigma, the various levels of technical proficiency required, criteria for selecting personnel for training, using customer requirements to drive strategy and operations, successful project management, and much more.For the manager or quality professional charged with implementing or supporting Six Sigma--no matter the industry--this timely guide will help any organization achieve the goal of becoming a truly world-class operation. Topics include: How to organize for Six Sigma How to use DMAIC to dramatically improve existing products and processes How to use Design for Six Sigma (DFSS) and Lean to create new, world-class products and processes Complete coverage of all major problem-solving and statistical tools and techniques, from basic to advanced tools such as DOE and logistic regression How to use MINITABTM and Microsoft Excel(R) to perform statistical analyses How to avoid common traps and pitfalls during implementation The Six Sigma management system is helping numerous companies improve the quality of their productsand processes. "The Six Sigma Handbook is the comprehensive reference guide you need to successfully implement Six Sigma. It describes the statistical tools and problem-solving techniques that comprise Six Sigma, explaining ho

Author Biography

Thomas Pyzdek is a Six Sigma consultant to Ford, McDonalds, Boeing Satellite Systems, Intuit, Avon Products, Federal Mogul, Tucson Medical Center and many others. He has over 30 years experience in the quality field. He writes the column Six Sigma and Beyond for Quality Digest magazine. Pyzdek was a member of the first Board of Examiners for the Malcolm Baldrige National Quality Award. He is a Fellow of ASQ and recipient of the ASQ Edwards Medal for outstanding contributions to the practice of quality management.

Table of Contents

Preface	p. xiii
Introduction	p. xvi
Six Sigma Implementation and Management	p. 1
Building the Six Sigma Infrastructure	p. 3
What is Six Sigma?	p. 3
Implementing Six Sigma	p. 20
Change agent compensation and retention	p. 54
Six Sigma Goals and Metrics	p. 56
Attributes of good metrics	p. 56
Six Sigma versus traditional three sigma performance	p. 58
The balanced scorecard	p. 61
Strategy deployment plan	p. 71
Information systems requirements	p. 74
Dashboard design	p. 79
Setting organizational key requirements	p. 89
Creating Customer-Driven Organizations	p. 97
Elements of customer-driven organizations	p. 97
Surveys and focus groups	p. 102
Calculating the value of retention of customers	p. 116
Kano model of customer expectations	p. 119
Quality function deployment (QFD)	p. 121
The Six Sigma process enterprise	p. 125
Using QFD to link Six Sigma projects to strategies	p. 132
Linking customer demands to budgets	p. 140
Training for Six Sigma	p. 150
Training needs analysis	p. 150
The strategic training plan	p. 152
Six Sigma Teams	p. 167
Six Sigma teams	p. 167
Process improvement teams	p. 168
Work groups	p. 169
Other self-managed teams	p. 170
Team dynamics management, including conflict resolution	p. 171
Facilitation techniques	p. 178
Team performance evaluation	p. 182
Team recognition and reward	p. 184
Selecting and Tracking Six Sigma Projects	p. 187
Choosing the right projects	p. 188
Analyzing project candidates	p. 189
Tracking Six Sigma project results	p. 208
Six Sigma Tools and Techniques	p. 235
Introduction to DMAIC and Other Improvement Models	p. 237
DMAIC, DMADV and learning models	p. 237
The Define Phase
Problem Solving Tools	p. 252
Process mapping	p. 252
Check sheets	p. 255
Pareto analysis	p. 259
Cause and effect diagrams	p. 261
7M tools	p. 264
The Measure Phase
Basic Principles of Measurement	p. 277
Scales of measurement	p. 277
Reliability and validity of data	p. 280
Overview of statistical methods	p. 283
Principles of statistical process control	p. 318
Measurement Systems Analysis	p. 325
R&R studies for continuous data	p. 325
Attribute measurement error analysis	p. 346
Repeatability and pairwise reproducibility	p. 352
The Analyze Phase
Knowledge Discovery	p. 361
Knowledge discovery tools	p. 361
Establishing the process baseline	p. 385
SIPOC	p. 383
Statistical Process Control Techniques	p. 393
Statistical process control (SPC)	p. 393
EWMA	p. 453
Process Capability Analysis	p. 467
Process capability analysis (PCA)	p. 467
Estimating process yield	p. 484
Statistical Analysis of Cause and Effect	p. 490
Testing common assumptions	p. 490
Regression and correlation analysis	p. 496
Analysis of categorical data	p. 514
Non-parametric methods	p. 528
The Improve Phase
Managing Six Sigma Projects	p. 534
Useful project management tools and techniques	p. 535
Project charter	p. 538
Work breakdown structures	p. 541
Feedback loops	p. 543
Performance measures	p. 544
Cost considerations in project scheduling	p. 552
Project management implementation	p. 560
Risk Assessment	p. 571
Reliability and safety analysis	p. 571
Failure mode and effect analysis (FMEA)	p. 596
Statistical tolerancing	p. 600
Design of Experiments (DOE)	p. 607
Terminology	p. 608
Power and sample size	p. 610
Design characteristics	p. 610
Types of design	p. 611
Examples of applying common DOE methods using software	p. 616
Empirical model building and sequential learning	p. 624
Data mining, artificial neural networks and virtual process mapping	p. 644
The Control Phase
Maintaining Control After the Project	p. 649
Business process control planning	p. 649
Using SPC for ongoing control	p. 652
Process control planning for short and small runs	p. 655
Preparing the short run process control plain (PCP)	p. 656
PRE-Control	p. 661
Beyond DMAIC
Design for Six Sigma (DFSS)	p. 665
Preliminary steps	p. 665
Define	p. 667
Measure	p. 670
Analyze	p. 671
Design	p. 682
Verify	p. 703
Lean Manufacturing and Six Sigma	p. 705
Introduction to Lean and muda	p. 705
What is value to the customer?	p. 706
What is the value stream?	p. 708
How do we make value flow?	p. 711
How do we make value flow at the pull of the customer?	p. 713
How can we continue towards perfection?	p. 716
Becoming Lean: A tactical perspective	p. 720
Six Sigma and Lean	p. 721
Appendix	p. 724
Glossary of basic statistical terms	p. 724
Area under the standard normal curve	p. 730
Critical values of the t-distribution	p. 733
Chi-square distribution	p. 735
F distribution ([alpha] = 1%)	p. 738
F distribution ([alpha] = 5%)	p. 740
Poisson probability sums	p. 742
Tolerance interval factors	p. 746
Durbin-Watson test bounds	p. 750
y factors for computing AOQL	p. 754
Control chart constants	p. 755
Control chart equations	p. 757
Table of d*[subscript 2] values	p. 759
Power functions for ANOVA	p. 761
Factors for short run control charts for individuals, X-bar, and R charts	p. 770
Significant number of consecutive highest or lowest values from one stream of a multiple-stream process	p. 772
Sample customer survey	p. 773
Process [sigma] levels and equivalent PPM quality levels	p. 777
Black Belt effectiveness certification	p. 778
Green Belt effectiveness certification	p. 791
AHP using Microsoft Excel	p. 804
References	p. 806
Index	p. 814
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