Implementing Lean Six Sigma Throughout the Supply Chain

by Cudney, Elizabeth A.; Kestle, Rodney

• ISBN13: 9781439828144
• ISBN10: 1439828148
• Format: Paperback
• Copyright: 2010-10-14
• Publisher: Productivity Pr

Summary

From start to finish, this book provides a comprehensive lean six sigma case study. The text follows a team as they implement a lean six sigma project and provides over illustrative 100 figures and tables. Unlike current published case studies, which give only an overview, this in-depth case study presents the data, which are also included in the accompanying CD, and comprehensively explains how the team drew their conclusions. The CD contains all of the data used throughout the case study, so that readers can make the same analyses. In addition, the authors demonstrate the clear linkages between all of the lean six sigma tools.

Table of Contents

Acknowledgments	p. xi
Authors	p. xiii
Introduction	p. 1
How To Use the CD	p. 2
CD Instructions	p. 2
Lean Six Sigma Overview	p. 5
Case Study Introduction	p. 11
Define Phase	p. 15
Introduction	p. 15
Midwest Logistics, Lean Six Sigma Core Team	p. 16
Develop Initial Documents	p. 19
Project Charter	p. 20
Supplier-Input-Process-Output-Customer (SIPOC)	p. 25
Identify Stakeholders and Develop Communication Plan	p. 28
Communications Strategy List	p. 32
Perform Initial VOC and Identify CTS	p. 35
Select the Team and Launch the Project	p. 39
Midwest Logistics, Lean Six Sigma Team Additions	p. 40
Create Responsibility Matrix (RASIC)	p. 41
Create Project Plan	p. 41
Measure Phase	p. 55
Introduction	p. 55
Define the Current Process	p. 56
Process Mapping	p. 64
Data Collection Plan, Metrics, and Operational Definitions	p. 84
Create a Baseline	p. 97
Define the Detailed Voice of the Customer (VOC)	p. 101
Interview Event	p. 101
Brainstorm Needs	p. 104
Affinity Diagrams	p. 105
Translate Needs to CTQ	p. 108
Survey Customers/Stakeholders	p. 115
Customer Needs Map	p. 116
Quality Function Deployment (QFD)	p. 138
Define the Voice of the Process (VOP) and Current Performance	p. 139
Benchmarking	p. 141
Check Sheets	p. 141
Plots, Capability and Statistics	p. 148
Pareto Charts, Time Series, Histograms	p. 149
Validate Measurement System	p. 159
Define the Cost of Poor Quality (COPQ) and Cost/Benefit	p. 164
Moving to the Analyze Phase	p. 164
Analyze Phase	p. 167
Introduction	p. 167
Develop Cause-and-Effect Relationships	p. 169
Test for Normality Exercise	p. 172
Process Analysis and 8 Wastes	p. 173
5S	p. 176
Failure Mode and Effects Analysis	p. 177
Determine and Validate Root Causes	p. 181
Regression Analysis	p. 196
Hypothesis Test	p. 196
Develop Process Capability	p. 196
Process Capability	p. 199
Improve Phase	p. 207
Introduction	p. 207
Identify Breakthrough and Select Practical Approaches	p. 208
Action (Pilot) Plan	p. 210
Perform Cost/Benefit Analysis	p. 211
Design Future State	p. 212
Establish Performance Targets and Project Scorecard	p. 214
Gain Approval to Implement, Then Implement	p. 222
Train and Execute	p. 222
Control Phase	p. 231
Introduction	p. 231
Measure Results and Manage Change	p. 232
Report Scorecard Data and Create Process Control Plan	p. 235
FMEA and Control Plan	p. 235
Process Capability/DPMO	p. 237
Apply P-D-C-A Process	p. 240
Identify Replication Opportunities	p. 242
Develop Future Plans	p. 244
Conclusions	p. 247
Lean Six Sigma Glossary	p. 249
Index	p. 261
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