Lean Six Sigma for dummies: [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities]
Saved in:
| Main Authors: | , |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
Chichester [u.a.]
Wiley
2012
|
| Edition: | 2. ed. |
| Series: | ... for dummies
|
| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Physical Description: | XVI, 300 S. Ill., graph. Darst. |
| ISBN: | 9781119953708 |
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| adam_text | Titel: Lean six sigma for dummies
Autor: Morgan, John
Jahr: 2012
Table of Contents
Introduction................................................................. 7
About This Book..............................................................................................1
Conventions Used in This Book.....................................................................2
Foolish Assumptions.......................................................................................2
How This Book Is Organised..........................................................................3
Part I: Lean Six Sigma Basics................................................................3
Part H: Working with Lean Six Sigma...................................................3
Part III: Assessing Performance...........................................................4
Part IV: Improving the Processes........................................................4
Part V: Deploying Lean Six Sigma........................................................5
Part VI: The Part of Tens.......................................................................5
Icons Used In This Book.................................................................................5
Where to Go From Here..................................................................................6
Part 1: Lean Sw Sigma Basics........................................ 7
Chapter 1: Defining Lean Six Sigma..............................9
Introducing Lean Thinking.............................................................................9
Bringing on the basics of Lean...........................................................10
Perusing the principles of Lean thinking..........................................15
Sussing Six Sigma...........................................................................................15
Considering the core of Six Sigma.....................................................16
Calculating process sigma values......................................................19
Meeting the major points of Six Sigma..............................................22
Chapter 2: Understanding the Principles of Lean Six Sigma........23
Considering the Key Principles of Lean Six Sigma....................................23
Improving Existing Processes: Introducing DMAIC...................................25
Defining your project...........................................................................26
Measuring how the work is done.......................................................32
Analysing your process.......................................................................32
Improving your process......................................................................33
Coming up with a control plan...........................................................33
Reviewing Your DMAIC Phases....................................................................34
Taking a Pragmatic Approach......................................................................37
Part 11: Working with Lean Six Sigma.......................... 41
Chapter 3: Identifying Your Customers...........................43
Understanding the Process Basics..............................................................43
Pinpointing the elements of a process..............................................44
Identifying internal and external customers....................................45
Getting a High-Level Picture.........................................................................47
Drawing a high-level process map.....................................................48
Segmenting customers........................................................................51
Chapter 4: Understanding Your Customers Needs................53
Can You Kano?...............................................................................................53
Obtaining the Voice of the Customer..........................................................55
Taking an outside-in view...................................................................55
Segmenting your customers...............................................................56
Prioritising your customers................................................................57
Researching the Requirements....................................................................57
Interviewing your customers.............................................................60
Focusing on focus groups...................................................................61
Considering customer surveys..........................................................62
Using observations..............................................................................63
Avoiding Bias.................................................................................................64
Considering Critical To Quality Customer Requirements........................65
Establishing the Real CTQs..........................................................................69
Prioritising the requirements.............................................................70
Measuring performance using customer-focused measures.........71
Chapter 5: Determining the Chain of Events......................73
Finding Out How the Work Gets Done........................................................73
Practising process stapling................................................................74
Drawing spaghetti diagrams...............................................................76
Painting a Picture of the Process.................................................................77
Keeping things simple.........................................................................79
Developing a deployment flowchart..................................................80
Seeing the value in a value stream map............................................84
Identifying moments of truth.............................................................93
Part HI: Assessing Performance...................................95
Chapter 6: Gathering Information...............................97
Managing by Fact...................................... 97
Realising the importance of good data.............................................98
Reviewing what you currently measure..........................................98
Deciding what to measure............... .............99
Developing a Data Collection Plan............................................................100
Beginning with output measures.....................................................100
Creating clear definitions..................................................................102
Agreeing rules to ensure valid and consistent data......................102
Collecting the data.............................................................................105
Identifying ways to improve your approach..................................107
An Introduction to Sampling......................................................................108
Process sampling...............................................................................109
Population sampling..........................................................................Ill
Chapter 7: Presenting Your Data...............................117
Delving into Different Types of Variation.................................................117
Understanding natural variation......................................................118
Spotlighting special cause variation................................................118
Distinguishing between variation types..........................................119
Avoiding tampering...........................................................................119
Displaying data differently................................................................120
Recognising the Importance of Control Charts.......................................121
Creating a control chart....................................................................122
Unearthing unusual features............................................................123
Choosing the right control chart.....................................................126
Examining the state of your processes...........................................127
Considering the capability of your processes...............................129
Additional ways to present and analyse your data.......................133
Testing Your Theories................................................................................135
Chapter 8: Analysing What s Affecting Performance.............139
Unearthing the Usual Suspects..................................................................139
Generating your list of suspects......................................................140
Investigating the suspects and getting the facts...........................142
Getting a Balance of Measures...................................................................143
Connecting things up........................................................................143
Proving your point.............................................................................145
Seeing the point.................................................................................146
Assessing your effectiveness............................................................148
Part IV: Improving the Processes............................... 153
Chapter 9: Identifying Value-Added Steps and Waste............155
Interpreting Value-Added...........................................................................155
Providing a common definition........................................................156
Carrying out a value-added analysis...............................................157
Assessing opportunity......................................................................160
Looking at the Seven Wastes.....................................................................160
Owning up to overproduction..........................................................161
Playing the waiting game..................................................................162
Troubling over transportation.........................................................162
Picking on processing.......................................................................162
Investigating inventory.....................................................................163
Moving on motion..............................................................................163
Coping with correction.....................................................................165
Looking Beyond the Seven Wastes............................................................165
Wasting people s potential...............................................................165
Going green.........................................................................................166
Considering customer perspectives................................................166
Focusing on the Vital Few...........................................................................167
Chapter 10: Discovering the Opportunity for Prevention..........169
Keeping Things Neat and Tidy...................................................................170
Introducing the Five Ss......................................................................170
Carrying out a red-tag exercise........................................................171
Using visual management.................................................................172
Looking at Prevention Tools and Techniques.........................................175
Introducing Jidoka.............................................................................175
Reducing risk with Failure Mode Effects Analysis (FMEA)...........176
Error proofing your processes.........................................................179
Profiting from Preventive Maintenance....................................................181
Avoiding Peaks and Troughs.....................................................................182
Introducing Heijunka.........................................................................182
Spreading the load.............................................................................183
Carrying out work in a standard way..............................................184
Chapter 11: Identifying and Tackling Bottlenecks................185
Applying the Theory of Constraints..........................................................185
Identifying the weakest link..............................................................185
Improving the process flow..............................................................186
Building a buffer.................................................................................188
Managing the Production Cycle.................................................................189
Using pull rather than push production.........................................189
Moving to single piece flow..............................................................190
Recognising the problem with batches..........................................191
Looking at Your Layout..............................................................................191
Identifying wasted movement..........................................................191
Using cell manufacturing techniques..............................................191
Identifying product families.............................................................193
Chapter 12: Introducing Design for Six Sigma...................195
Introducing DfSS..........................................................................................196
Introducing DMADV..........................................................................196
Defining What Needs Designing.................................................................197
Getting the measure of the design...................................................198
Analysing the design.........................................................................198
Developing the design.......................................................................200
Verifying that the design works.......................................................200
Choosing between DMAIC and DMADV..........................................201
Considering Quality Function Deployment..............................................202
What are these houses and rooms all about?................................203
Undertaking a QFD drill-down.........................................................212
Decisions, Decisions....................................................................................213
Part V: Deploying Lean Six Sigma..............................217
Chapter 13: Leading the Deployment...........................219
Key Factors for Successful Deployment ..................................................220
Executive Sponsorship...............................................................................220
A Few Words about Size.............................................................................222
The Deployment Programme Manager....................................................223
Lean Six Sigma Start Up..............................................................................225
Project Champions......................................................................................226
Chapter 14: Selecting the Right Projects........................229
Generating a List of Candidate Improvement Projects...........................229
Working Out if Lean Six Sigma Is the Right Approach............................232
Prioritising projects...........................................................................233
Using a Criteria Selection Matrix.....................................................234
Deciding on which approach fits which project:
Doing the work right.....................................................................236
Setting up a DMAIC Project........................................................................237
Seeing Rapid Improvement with a Kai Sigma Event................................238
Chapter 15: Understanding the People Issues...................241
Working Right Right from the Start.........................................................241
Gaining Acceptance.....................................................................................242
Managing change...............................................................................242
Overcoming resistance.....................................................................244
Creating a Vision..........................................................................................245
Understanding Organisational Culture.....................................................247
Busting Assumptions..................................................................................248
Seeing how People Cope with Change......................................................249
Comparing energy and attitude.......................................................250
Using a forcefield diagram................................................................251
Analysing your stakeholders............................................................251
Focusing on key elements of change...............................................253
Chapter 16: Ten Best Practices................................257
Lead and Manage the Programme.............................................................257
Appreciate that Less Is More.....................................................................258
Build in Prevention......................................................................................259
Challenge Your Processes..........................................................................260
GototheGemba..........................................................................................261
Manage Your Processes with Lean Six Sigma..........................................261
Pick the Right Tools for the Job................................................................262
Tell the Whole Story....................................................................................263
Understand the Role of the Champion.....................................................264
Looking at the Lean Six Sigma programme business
champion.........................................................................................264
Perusing the role of the project champion.....................................264
Use Strategy to Drive Lean Six Sigma........................................................265
Chapter 17: Ten Pitfalls to Avoid...............................267
Jumping to Solutions...................................................................................267
Coming Down with Analysis Paralysis......................................................268
Falling into Common Project Traps..........................................................269
Methodology madness......................................................................269
Scope scandals...................................................................................269
Team turmoil......................................................................................270
Lack of support..................................................................................270
Stifling the Programme Before You ve Started........................................270
Ignoring the Soft Stuff..................................................................................271
Getting Complacent.....................................................................................271
Thinking We re Already Doing It ..............................................................272
Believing the Myths.....................................................................................272
Doing the Wrong Things Right...................................................................273
Overtraining.................................................................................................274
Chapter 18: Ten Places to Go for Help..........................275
Your Colleagues...........................................................................................275
Your Champion............................................................................................276
Other Organisations............................. .................................276
The Internet.................................................. ..............................................276
Networks and Associations................................................................278
Conferences..................................................................................................278
Books.............................................................................................................278
Periodicals....................................................................................................279
Software........................................................................................................280
Statistical analysis.............................................................................280
Deployment management.................................................................281
Training and Consultancy Companies......................................................281
Index.......................................................................283
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| isbn | 9781119953708 |
| language | English |
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| spelling | Morgan, John Verfasser aut Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] by John Morgan and Martin Brenig-Jones 2. ed. Chichester [u.a.] Wiley 2012 XVI, 300 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier ... for dummies Lean Management (DE-588)4300840-9 gnd rswk-swf Six Sigma (DE-588)7604241-8 gnd rswk-swf Lean Management (DE-588)4300840-9 s Six Sigma (DE-588)7604241-8 s DE-604 Brenig-Jones, Martin Verfasser aut Erscheint auch als Online-Ausgabe 978-1-119-96646-3 Erscheint auch als Online-Ausgabe 978-1-119-96647-0 Erscheint auch als Online-Ausgabe 978-1-119-96648-7 HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=024890934&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Morgan, John Brenig-Jones, Martin Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] Lean Management (DE-588)4300840-9 gnd Six Sigma (DE-588)7604241-8 gnd |
| subject_GND | (DE-588)4300840-9 (DE-588)7604241-8 |
| title | Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] |
| title_auth | Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] |
| title_exact_search | Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] |
| title_full | Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] by John Morgan and Martin Brenig-Jones |
| title_fullStr | Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] by John Morgan and Martin Brenig-Jones |
| title_full_unstemmed | Lean Six Sigma for dummies [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] by John Morgan and Martin Brenig-Jones |
| title_short | Lean Six Sigma for dummies |
| title_sort | lean six sigma for dummies learn to enhance business efficiency and reduce waste successfully deploy lean six sigma projects in your organisation manage projects more tightly and fine tune existing systems apply lean six sigma thinking to your day to day activities |
| title_sub | [Learn to: enhance business efficiency and reduce waste ; successfully deploy Lean Six Sigma projects in your organisation ; manage projects more tightly and fine-tune existing systems ; apply Lean Six Sigma thinking to your day-to-day activities] |
| topic | Lean Management (DE-588)4300840-9 gnd Six Sigma (DE-588)7604241-8 gnd |
| topic_facet | Lean Management Six Sigma |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=024890934&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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