Six Sigma+Lean Toolset : Executing Improvement Projects Successfully

by John, Alexander; Meran, Renata; Roenpage, Olin; Staudter, Christian; Lunau, Stephan; Schmitz, Astrid

• ISBN13: 9783540323495
• ISBN10: 354032349X
• Format: Hardcover
• Copyright: 2009-02-03
• Publisher: Springer Verlag

Summary

The Six Sigma concept has enjoyed triumphant success throughout the business world over the last 20 years, contributing significantly to renowned corporations improving their net income. For a number of years now this successful concept has been supplemented by the tools of Lean Management, an approach that has accelerated process speed, reduced inventories, and decreased lead times. As practiced by the authors of this book the Six Sigma+Lean approach combines the tried-and-tested tools of both worlds, which are linked together systematically in the proven DMAIC process model.The toolset is a comprehensive collection of the relevant Six Sigma+Lean tools necessary for successful project work. All of the tools are presented clearly and concisely in examples. The chronology matches that of the approach taken in a Six Sigma+Lean improvement project, following the steps Define, Measure, Analyze, Improve, and Control. This unique layout and structure has created a book ideal for practical use, enabling the reader to quickly find the right tools for a problem and concrete guidelines on how to apply them.

Table of Contents

Foreword	p. 1
Introduction	p. 3
The Formula for Success	p. 5
Quality as Success Factor	p. 7
Acceptance as Success Factor	p. 18
Management Commitment as Success Factor	p. 23
Result: Measurable, Sustainable Success	p. 26
Define	p. 27
Project Charter	p. 30
SIPOC	p. 34
Customer Orientation	p. 36
Research Methods for Collecting Customer Needs	p. 37
Customer Voice Chart	p. 38
Kano Model	p. 39
Tool 1: CTQ Matrix	p. 42
Tool 1: CTB Matrix	p. 44
Stakeholder Analysis	p. 46
Kick-Off Meeting	p. 48
Gate Review	p. 50
Checklist for the Define Phase	p. 52
Measure	p. 53
Tool 2: Measurement Matrix	p. 56
Data Collection Plan	p. 58
Operational Definition	p. 60
Data Sources and Type	p. 63
Sampling Strategy	p. 65
Data Collection Forms	p. 69
Measurement System Analysis	p. 71
Gage R & R for Discrete (Binary) Data	p. 74
Gage R & R ANOVA for Continuous Data	p. 76
Variation	p. 79
Graphs and Charts	p. 80
Location and Spread Parameters	p. 95
Process Capability Calculation	p. 102
Checklist for the Measure Phase	p. 119
Analyze	p. 121
Cause & Effect Diagram	p. 124
FMEA	p. 126
Process Mapping	p. 132
Interface Analysis	p. 136
Spaghetti Diagram	p. 138
Value Analysis	p. 140
Time Analysis	p. 143
Value Stream Map	p. 145
The Importance of Speed	p. 149
Identifying Process Constraints	p. 152
Tool 3: Input-Process Measurement Matrix	p. 154
Data Stratification	p. 156
Transforming Data	p. 158
Hypothesis Testing	p. 161
ANOVA	p. 168
Correlation	p. 176
Linear Regression	p. 178
DOE - Design of Experiments	p. 185
Analyze Closure Matrix	p. 200
Checklist for the Analyze Phase	p. 201
Improve	p. 203
Theory of Constraints - TOC	p. 206
5 S	p. 208
Setup Time Reduction	p. 211
Generic Pull System	p. 214
Replenishment Pull System	p. 217
Poka Yoke	p. 222
Total Productive Maintenance - TPM	p. 225
Lean for Service	p. 229
Creativity Techniques	p. 232
Tools for Selecting Solutions	p. 241
Implementation Planning	p. 252
Pilot Program	p. 262
Roll Out	p. 264
Checklist for the Improve Phase	p. 265
Control	p. 267
Process Documentation	p. 270
Monitoring/Visual Process Monitoring and Control	p. 272
Monitoring/Control Charts	p. 274
Reaction Plan	p. 283
Checklist for the Control Phase	p. 285
Project Documentation	p. 286
Project Closure	p. 288
Kaizen DMAIC	p. 289
Appendix
Abbreviations	p. 293
Index	p. 296
Sigma Value Table	p. 315
Table of Contents provided by Ingram. All Rights Reserved.