The Lean Six Sigma Pocket Toolbook: A Quick Reference Guide to Nearly 100 Tools for Improving Quality and Speed

by George, Michael; Maxey, John; Rowlands, David; Price, Mark

• ISBN13: 9780071441193
• ISBN10: 0071441190
• Edition: 1st
• Format: Paperback
• Copyright: 2004-10-13
• Publisher: McGraw Hill

Summary

Bestselling Lean Six Sigma author Michael George provides the first pocket guide for deployers of Lean Six Sigma The Lean Six Sigma Pocket Toolbookblends Lean and Six Sigma tools and concepts, providing expert advice on how to determine which tool within a "family" is best for different purposes. Packed with detailed examples and step-bystep instructions, it's the ideal handy reference guide to help Green and Black Belts make the transition from the classroom to the field. Features brief summaries and examples of the 70 most important tools in Lean Six Sigma, such as "Pull," "Heijunka," and "Control Charts" Groups tools by purpose and usage Offers a quick, easy reference on using the DMAIC improvement cycle Provides comprehensive coverage in a compact, portable format

Author Biography

Michael L. George (Dallas, TX) is the president of George Group and author of Lean Six Sigma and Lean Six Sigma for Service. John Maxey is a director at George Group. David Rowlands is the vice president of Lean Six Sigma for the North American Solutions Group, the sales, service, and marketing arm of Xerox. Malcolm Upton is a Lean Six Sigma Master Black Belt with George Group.

Table of Contents

Chapter 1: Using DMAIC to Improve Speed, Quality, and Cost	1	(26)
Define	4	(4)
Measure	8	(4)
Analyze	12	(2)
Improve	14	(3)
Control	17	(3)
Kaizen DMAIC	20	(6)
Project selection	26	(1)
Chapter 2: Working With Ideas	27	(6)
Brainstorming	27	(3)
Affinity diagrams	30	(1)
Multivoting	31	(2)
Chapter 3: Value Stream Mapping and
Process Flow Tools	33	(1)
Process mapping	34	(2)
Process observation	36	(2)
SIPOC	38	(1)
Process mapping steps	39	(3)
Transportation and spaghetti (workflow) diagrams	42	(1)
Swim-lane (deployment) flowcharts	43	(2)
Value stream maps (basic)	45	(4)
Flowchart and value stream symbols	49	(1)
Value-add (VA) vs. non-value-add (NVA) analysis	49	(3)
Time value maps	52	(1)
Value-add chart (task time or take time chart)	53	(2)
Chapter 4: Voice of the Customer (VOC)	55	(14)
Customer segmentation	56	(2)
Sources of customer data	58	(1)
Collecting VOC: Interviews	59	(1)
Collecting VOC: Point-of-use observation	60	(1)
Collecting VOC: Focus groups	61	(1)
Collecting VOC: Surveys	62	(2)
Kano analysis	64	(3)
Developing critical-to-quality requirements	67	(2)
Chapter 5: Data Collection	69	(35)
Types of data	70	(1)
Input vs. output data	71	(1)
Data collection planning	72	(2)
Measurement selection matrix	74	(1)
Stratification factors	75	(1)
Operational definitions	76	(1)
Cautions on using existing data	77	(1)
Making a checksheet	78	(1)
Basic checksheets	79	(1)
Frequency plot checksheet	80	(1)
Traveler checksheet	80	(1)
Location checksheet	81	(1)
Sampling basics	81	(2)
Factors in sample selection	83	(1)
Stable process (and population) sampling	84	(1)
Formulas for determining minimum sample size (population or stable process)	85	(2)
Measurement System Analysis (MSA) and Gage R&R Overview	87	(1)
Gage R&R: Collecting the data	88	(2)
Interpreting Gage R&R Results	90	(6)
MSA: Evaluating bias	96	(1)
MSA: Evaluating stability	97	(2)
MSA: Evaluating discrimination	99	(1)
MSA for attribute/discrete data	100	(4)
Chapter 6: Descriptive Statistics and Data Displays	104	(13)
Statistical term conventions	105	(1)
Measures of central tendency (mean, median, mode)	106	(2)
Measures of spread (range, variance, standard deviation)	108	(2)
Boxplots	110	(1)
Frequency plot (histogram)	111	(3)
Normal distribution	114	(1)
Non-normal distributions and the Central Limit Theorem	114	(3)
Chapter 7: Variation Analysis	117	(24)
Review of variation concepts	118	(1)
Time series plots (Run charts)	119	(2)
Run chart table	121	(1)
Control chart basics	122	(1)
Selecting a control chart	123	(1)
Control charts for continuous data	123	(2)
Subgrouping for continuous data	125	(2)
Control limit formulas for continuous data	127	(1)
Factors for Control Chart Formulas	128	(1)
Creating an ImR Chart	128	(1)
Creating X,R charts or X,S charts	129	(1)
Control charts for attribute data	130	(2)
Creating p-, np-, c-, and u-charts	132	(1)
Control limit formulas for attribute data	132	(1)
Assumptions for interpreting control charts	133	(1)
Interpreting control charts (Tests for Special Cause Variation)	133	(2)
Background on process capability calculations	135	(2)
Confusion in short-term vs. long-term process capability calculations	137	(1)
Calculating process capability	138	(3)
Chapter 8: Identifying and Verifying Causes	141	(56)
PART A: Identifying potential causes	141	(8)
Pareto charts	142	(3)
5 Whys	145	(1)
Cause-and-effect diagrams (fishbone or Ishikawa diagrams)	146	(2)
C&E Matrix	148	(1)
PART B: Tools for confirming causal effects	149	(48)
Stratified data charts	150	(2)
Testing quick fixes or obvious solutions	152	(2)
Scatter plots	154	(2)
Hypothesis testing overview	156	(1)
Confidence intervals	157	(1)
Type I and Type II errors, Confidence, Power, and p-values	158	(2)
Confidence intervals and sample size	160	(1)
t-test Overview	161	(1)
1-Sample t-test	162	(1)
2-Sample t-test	163	(2)
Overview of correlation	165	(1)
Correlation statistics (coefficients)	166	(1)
Regression overview	167	(1)
Simple linear regression	168	(1)
Multiple regression	169	(4)
ANOVA (ANalysis Of VAriance)	173	(1)
One-way ANOVA	174	(4)
Degrees of Freedom	178	(1)
ANOVA assumptions	179	(1)
Two-way ANOVA	180	(2)
Chi-Square test	182	(2)
Design of Experiments (DOE) notation and terms	184	(1)
Planning a designed experiment	185	(4)
DOE: Full-factorial vs. Fractional-factorials (and notations)	189	(3)
Interpreting DOE results	192	(3)
Residual analysis in hypothesis testing	195	(2)
Chapter 9: Reducing Lead Time and Non-Value-Add Cost	197	(44)
Basic Lean concepts	199	(2)
Metrics of time efficiency	201	(2)
Time Traps vs. Capacity Constraints	203	(1)
Identifying Time Traps and Capacity Constraints	204	(2)
5S Overview	206	(1)
Implementing 5S	207	(6)
Generic Pull System	213	(3)
Replenishment Pull Systems	216	(3)
Two-Bin Replenishment System	219	(3)
Computing minimum safe batch sizes	222	(1)
Four Step Rapid Setup Method	223	(4)
Adapting Four Step Rapid Setup for service processes	227	(1)
Total Productive Maintenance (TPM)	228	(4)
Mistake proofing & prevention (Poky yoke)	232	(2)
Process balancing design principles	234	(1)
Work cell optimization	235	(2)
Visual Process Controls	237	(4)
Chapter 10: Complexity Value Stream Mapping and Complexity Analysis	241	(12)
Product/service family grid	242	(1)
Complexity Value Stream Map (CVSM)	243	(2)
Process Cycle Efficiency (PCE)	245	(1)
The Complexity Equation	245	(1)
Complexity matrix	246	(1)
PCE destruction calculations (for a Complexity Matrix)	247	(1)
Substructure analysis	248	(2)
"What-if' analyses with Complexity Matrix data	250	(3)
Chapter 11: Selecting and Testing Solutions	253	(24)
Sources of solution ideas	254	(1)
Benchmarking	254	(1)
Tips on solution selection	255	(1)
Developing and using evaluation criteria	256	(2)
Solution selection matrix	258	(3)
Pairwise ranking	261	(3)
Cost evaluation	264	(1)
Impact/effort matrix	264	(1)
Pugh matrix	265	(4)
Other evaluation techniques	269	(1)
Controls assessment matrix	269	(1)
Failure Modes and Effects Analysis (FMEA)	270	(3)
Pilot testing	273	(4)
Index	277