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9780071411837

The Six Sigma Project Planner A Step-by-Step Guide to Leading a Six Sigma Project Through DMAIC

by
  • ISBN13:

    9780071411837

  • ISBN10:

    0071411836

  • Edition: 1st
  • Format: Paperback
  • Copyright: 2003-04-11
  • Publisher: McGraw-Hill Education
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Supplemental Materials

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Summary

The Six Sigma Project Planner is designed to be used by the leaders of a Six Sigma initiative, to plan and implement prioritized Six Sigma projects. It guides leaders through selecting the quality improvement projects that will have the biggest payoff, measuring and analyzing a problem, and implementing solutions. Teams who are assigned projects will use the Six Sigma Project Planner to plan and manage individual projects. The Planner follows the Define-Measure-Analyze-Improve- Control (DMAIC) Six Sigma format for process improvement, and enables organizations to take a project management approach to a Six Sigma roll-out.

Author Biography

Thomas Pyzdek is among the world's leading experts in Six Sigma and TQM. The recipient of ASQ's prestigious Edwards Medal for outstanding contributions to quality management, he is the author of The Six Sigma Handbook.

Table of Contents

List of Figuresp. viii
List of Tablesp. ix
List of Worksheetsp. ix
Prefacep. xiii
Introductionp. xiv
How to Use The Six Sigma Plannerp. xiv
Planningp. 1
Develop the Project Charterp. 1
Project Charterp. 1
The Project Charter Documentp. 1
Conduct a Feasibility Analysisp. 5
Is This a Valid Projectp. 5
Feasibility Analysis Studyp. 8
The Project Planp. 16
Project Metricsp. 16
Refining the Dollar Opportunity Estimatesp. 20
How Will I Monitor Satisfaction with Project Success?p. 22
Identify Human Resources Need to Complete the Projectp. 24
Identify Other Resources Needed to Complete the Projectp. 27
Work Breakdown Structuresp. 29
Creating the WBSp. 29
Integration and Testp. 32
Project Schedule Developmentp. 32
Activity Definitionp. 35
Activity Dependenciesp. 38
Estimating Activity Durationp. 40
Gantt Chartsp. 42
Network Diagramsp. 46
Resource Availabilityp. 51
Calendarsp. 51
Schedule Improvementp. 54
Estimating Project Duration Statisticallyp. 60
Calculating the Cost of a Schedulep. 66
Resource Levelingp. 70
Project Control Subplansp. 72
Risk Control Planp. 72
Quality Planp. 80
Cost Control Planp. 84
Schedule Control Planp. 87
Project Schedule Managementp. 88
Scope Change Control Planp. 90
Change Control Systemp. 90
Definep. 95
What Is the Current State?p. 95
What's Wrong with the Way Things are Now?p. 96
Quantify the Undesirable Effectsp. 97
Tools and Techniquesp. 97
Failure Mode and Effect Analysis (FMEA)p. 100
FMEA Processp. 100
Process Metricsp. 106
Other Key Factors and Metricsp. 110
How Does This Project Move the Organization Toward Its Strategic Goals and Objectives?p. 111
Measure
Measurement Reliability and Validityp. 113
Dimension Measurement Analysisp. 113
Attribute Measurement Analysisp. 115
Analyzep. 119
Quantify the Current Processp. 119
Catalog of Data Sources for This Processp. 119
Exploratory Data Analysisp. 121
Descriptive Data Analysisp. 122
Example of Using Worksheetp. 124
Quantify the Capability of the Current Processp. 125
Conduct a Process Auditp. 125
Prepare an Audit Reportp. 129
Determine Sigma and DPMO Levels CTx'sp. 129
Process Capability and Process Actual Sigma Levels Continuous CTx Characteristicsp. 129
Measuring Process Capability for Variables Datap. 129
Measuring Actual Process Performance for Variables Datap. 130
Process Capability and Process Actual Sigma Levels for Attribute CTx Characteristicsp. 131
Measuring Process Capability for Attributes Datap. 132
Measuring Actual Process Performance for Variables Datap. 132
Improvep. 139
Optimize the Processp. 139
Perform Designed Experimentsp. 141
What Will the Future State Be?p. 144
What are the Best Practices in This Area?p. 144
Create a Future State Process Mapp. 150
Six Sigma Project Activities Templatep. 152
Presentation and Acceptance of Deliverablesp. 154
Controlp. 157
Control Failure Mode and Effect Analysis (FMEA)p. 157
Business Process Control Systemsp. 159
How Will We Maintain the Gains Made?p. 159
A Tutorial on Project Selection and Managementp. 165
Choosing the Right Projectsp. 165
Customer Value Projectsp. 166
Using QFD to Link Six Sigma Projects to Strategiesp. 166
The Strategy Deployment Planp. 168
Using Customer Demands to Design For Six Sigmap. 174
Structured Decision-Makingp. 175
Shareholder Value Projectsp. 184
Other Six Sigma Projectsp. 184
Analyzing Project Candidatesp. 184
Other Methods of Identifying Promising Projectsp. 184
Using Pareto Analysis to Identify Six Sigma Candidatesp. 185
Throughput-Based Project Selectionp. 186
Multitasking and Project Schedulingp. 190
Critical Chain Project Portfolio Managementp. 191
Summary and Preliminary Project Selectionp. 192
Tracking Six Sigma Resultsp. 194
Financial Results Validationp. 196
Types of Savingsp. 196
Lessons Learned: Capture and Replicationp. 196
Appendicesp. 199
Issues Listp. 200
Risk Control Planp. 202
Quality Planp. 203
Cost Control Planp. 204
Schedule Control Planp. 205
Project Change Control Planp. 206
Audit Reportp. 207
Business Process Change Control Planp. 208
Resource Calendarsp. 209
Attribute Measurement Error Analysisp. 210
Calculating Yieldsp. 224
Normalized Yield and Sigma Levelp. 227
Analytic Hierarchy Process (AHP) Using MS Excelp. 230
Additional Resources on Six Sigma Project Managementp. 232
Figures
The Six Sigma Project Process Flowp. xv
Map of Six Sigma Project Flowp. xvii
Six Sigma Project DMAIC Cycle Questionsp. xviii
Example of Project Validation Analysisp. 6
Example of Cost-Benefit Opportunity Calculationsp. 20
WBS Creation Process Flowchartp. 29
Example of a WBSp. 30
Types of Activity Dependenciesp. 38
Gantt Chart of Schedulep. 42
Gantt/Milestone Chart of Actual vs. Scheduled Performancep. 42
Example of Computer Gantt/Milestone Chartp. 43
Example of Network Diagramp. 48
Example of a Computer-Generated Network Diagramp. 49
Example of a Computer-Generated Human Resource Calendarp. 52
Computer Screen for Entering Task Duration Datap. 63
Results of Simulation for Examplep. 64
Simulation Results: Probability of Meeting Due Datep. 65
Example of Cross-Functional Process Mapp. 95
Define Gate Criteriap. 112
Measure Gate Criteriap. 118
Some EDA Techniquesp. 121
Example of Combined DDA and EDA Analysisp. 122
Example of Evaluating a Hypothesisp. 124
Analyze Gate Criteriap. 137
Example of a Future State Process Mapp. 150
Improve Gate Criteriap. 156
Control Gate Criteriap. 164
Strategy Deployment Planp. 167
Strategy Deployment Matrixp. 168
QFD Relationship Weights and Symbolsp. 169
Phase II Matrix: Differentiatorsp. 171
Phase III Matrix: Six Sigma Projectsp. 173
Linkage Between Six Sigma Projects and Stakeholdersp. 174
Customer Demand Modelp. 178
Matrix of Categories for Pairwise Comparisonsp. 180
Completed Top-Level Comparison Matrixp. 181
A Simple Process with a Constraintp. 187
Critical Chain Scheduling Illustrationp. 193
Lithography Inspection Station Table, Stool, and Magnifying Glassp. 215
Attribute Gauge R&R Dialog Box and Data Layoutp. 219
MINITAB "Agreement Within Appraiser"p. 220
Plot of "Agreement Within Appraiser"p. 220
MINITAB "Agreement of Appraiser with Standard"p. 221
Plot of "Agreement of Appraiser with Standard"p. 221
MINITAB "Appraiser Disagreement"p. 222
MINITAB "Agreement Between Appraisers"p. 222
MINITAB "Assessment vs. Standard Agreement Across All Appraisers"p. 223
Excel Spreadsheet for RTYp. 225
Excel Spreadsheet for Calculating Normalized Yieldp. 227
Finding RTY Using Simulation Softwarep. 229
Tables
Instructions for Completing the Project Charter Statement Formp. 4
Strategies for Meeting the Project Goalsp. 24
Tools Useful in Risk Assessmentp. 75
Risk Planning vs. Impact and Likelihood of Threatening Eventsp. 75
Risk Response Planning Toolsp. 78
FMEA Severity, Likelihood, Detectibility Rating Guidelinesp. 102
FMEA Informationp. 104
Phases in Process Optimizationp. 141
Typical DMAIC Project Tasks and Responsibilitiesp. 152
Local and Global Importance Weightsp. 182
Example of Using Global Weights in Assessing Alternativesp. 183
Dysfunctional Process Symptoms and Underlying Diseasesp. 185
Illustration of the Pareto Priority Index (PPI)p. 186
Throughput Priority of CTx Projects That Affect the Constraintp. 189
Project Throughput Priority vs. Project Focusp. 189
Possible Information to Be Capturedp. 195
A Typical View of Six Sigma Projectsp. 195
Attribute Measurement Conceptsp. 210
Methods of Evaluating Attribute Inspectionp. 213
Results of Lithography Attribute Inspection Studyp. 215
Inspector Accuraciesp. 216
Repeatability and Pairwise Reproducibility for Both Days Combinedp. 216
Stability Analysisp. 217
Calculations Used to Find RTYp. 224
Worksheets
Project Charter Statementp. 2
Project Validation Analysisp. 7
Six Sigma Project Evaluationp. 9
Six Sigma Project Evaluation Guidelinesp. 10
Project Budget Developmentp. 17
Deliverables Metricsp. 19
Dollar Opportunity Estimatep. 21
Project Progress Satisfaction Metricsp. 23
Human Resources Assessmentp. 26
Project Resource Planningp. 28
Project Work Breakdown Structurep. 31
List of Penalties for Missing Deadlinep. 33
Major Milestones and Target Datesp. 34
Historical Research Summaryp. 36
Constraint Analysisp. 37
Activity Dependenciesap. 39
Activity Duration Estimatesp. 41
List of Activitiesp. 44
Project Gantt/Milestone Chart Templatep. 45
Project Gantt/Milestone Chart (Freehand Drawing Format)p. 46
Network Diagram for Projectp. 50
Resource Availability Informationp. 53
Schedule Improvement Evaluationp. 55
Best-Case, Expected, and Worst-Case Schedule Completion Datesp. 59
Statistical Analysis of Project Durationp. 62
Estimated Cost by Activity Durationp. 67
Cost-Optimization Spreadsheet Resultsp. 68
Cost-Optimization Graphical Analysisp. 69
Resource Levelingp. 71
Risk Event Classificationp. 76
New Opportunitiesp. 77
Risk Response Plansp. 79
Quality Plan Itemsp. 82
Project Budget Reports and Reporting Frequencyp. 86
Activity Status Management Reportp. 89
Change Control Informationp. 90
Controlled Documents Listp. 90
Current Process Mapp. 96
Narrative Description of Undesirable Effectsp. 96
Undesirable Effectsp. 99
FMEA Worksheetp. 105
CTQ Characteristicsp. 108
CTS and CTC Characteristicsp. 109
Other Key Factors and Metricsp. 110
Linkages to Enterprise Strategic Goalsp. 111
Gauge R&R Resultsp. 114
Attribute Inspection System Resultsp. 116
Attribute Inspection Results by Inspectorp. 117
Information Resource Catalogp. 120
DDA/EDA-Based Theories to Investigate Furtherp. 123
Process Audit Check Sheetp. 126
Actual CTx DPMO and Sigma Levelsp. 134
Capability Levels of Performancep. 135
Rolled Throughput Yield Analysisp. 136
Optimum Levels of Performancep. 142
Optimum Rolled Throughput Yieldsp. 143
Benchmarking Step 1: Identify What Is to Be Benchmarkedp. 144
Benchmarking Step 2: Identify Comparative Companiesp. 145
Benchmarking Step 3: Determine Data Collection Methodsp. 146
Benchmarking Step 4: Collect Data on Benchmarkp. 147
Benchmarking Step 5: Determine the Current Performance Gapp. 148
Benchmarking Step 6: Identify Causes of the Performance Gapp. 148
Benchmarking Step 7: Estimate Future Performance Levelsp. 149
Benchmarking Step 8: Establish Functional Goals and Gain Acceptance of Stakeholdersp. 149
Alternative Future State Process Mapsp. 151
Future State Improvement Estimatesp. 151
Deliverables Acceptance Reportp. 155
Control FMEA Worksheetp. 158
Additional Business Process Change Control Mechanismsp. 162
Project Assessment Summaryp. 194
Issues Listp. 200
Rolled Throughput Yields Worksheetp. 226
Table of Contents provided by Rittenhouse. All Rights Reserved.

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