Six Sigma for powerful improvement: a green belt DMAIC training system with software tools and a 25-lesson course
Gespeichert in:
| 1. Verfasser: | |
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| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
Boca Raton, Fla. [u.a.]
CRC Press
2013
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| Schlagworte: | |
| Online-Zugang: | Cover image Inhaltsverzeichnis |
| Beschreibung: | "The book follows Six Sigma's Define-Measure-Analyze-Improve-Control (DMAIC) procedures and tools. It will provide you with reasons for using the tools, underlying doctrine, and the formulas and steps, themselves"-- Provided by publisher. Includes bibliographical references and index |
| Beschreibung: | XLIX, 473 S. Ill., graph. Darst. 1 CD-ROM (12 cm) |
| ISBN: | 9781466564695 |
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| 245 | 1 | 0 | |a Six Sigma for powerful improvement |b a green belt DMAIC training system with software tools and a 25-lesson course |c Charles T. Carroll |
| 264 | 1 | |a Boca Raton, Fla. [u.a.] |b CRC Press |c 2013 | |
| 300 | |a XLIX, 473 S. |b Ill., graph. Darst. |e 1 CD-ROM (12 cm) | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 500 | |a "The book follows Six Sigma's Define-Measure-Analyze-Improve-Control (DMAIC) procedures and tools. It will provide you with reasons for using the tools, underlying doctrine, and the formulas and steps, themselves"-- Provided by publisher. | ||
| 500 | |a Includes bibliographical references and index | ||
| 650 | 4 | |a Wirtschaft | |
| 650 | 4 | |a Six sigma (Quality control standard) |v Textbooks | |
| 650 | 7 | |a BUSINESS & ECONOMICS / General |2 bisacsh | |
| 650 | 7 | |a TECHNOLOGY & ENGINEERING / Manufacturing |2 bisacsh | |
| 650 | 7 | |a TECHNOLOGY & ENGINEERING / Quality Control |2 bisacsh | |
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| adam_text | Titel: Six Sigma for powerful improvement
Autor: Carroll, Charles T
Jahr: 2013
Contents
List of Figures...........................................................................................................................................................xix
List of Tables...........................................................................................................................................................xxxv
Preface..................................................................................................................................................................xxxvii
Introduction..........................................................................................................................................................xxxix
Author......................................................................................................................................................................xlix
SECTION I DEFINE PHASE
1 Define Phase Overview........................................................................................................................................3
Contents......................................................................................................................................................................3
Define Phase Orientation within DMAIC...................................................................................................................3
Define Phase Objectives...............................................................................................................................................3
2 Identify Preliminary Requirements: Step 1.........................................................................................................5
Contents......................................................................................................................................................................5
ID Preliminary Requirements Orientation within DMAIC........................................................................................5
The Define Phase................................................................................................................................................5
Identification of CTQ Requirements of Your Customer..............................................................................................6
Sources of Customer Data..................................................................................................................................7
Voice of the Customer........................................................................................................................................7
Determining the VOC.................................................................................................................................................8
CTQ Capture Guidelines...................................................................................................................................8
What Is a Requirement?............................................................................................................................9
The Benefit of Stating Requirements Rather than Perceived Solutions: Two True Examples.....................9
Requirements Must Be Measurable.........................................................................................................10
Summary...................................................................................................................................................................13
3 Tool Training: Voice of the Customer...............................................................................................................15
Contents....................................................................................................................................................................15
What Is the Voice of the Customer?...........................................................................................................................15
Why Care about the Voice of the Customer?.............................................................................................................16
Where Do You Hear the Voice of Your Customer?....................................................................................................16
The VOC Listening Process.......................................................................................................................................16
Role of Customer Segmentation in VOC Listening Strategies..........................................................................16
Information Segmentation/Categorization........................................................................................................17
How Should You Listen to Customers?.............................................................................................................17
Interviews.........................................................................................................................................................18
Focus Groups....................................................................................................................................................18
Surveys.............................................................................................................................................................19
Open-Ended Questions...........................................................................................................................19
Response Scale—Types of Questions.........................................................................................................20
Likert Scale—Type Questions...................................................................................................................20
Self Anchored Scale Questions................................................................................................................20
Tool Selection and Using Tools in Combination..............................................................................................23
Sampling Bias............................................................................................................................................................24
Instrumentation Bias........................................................................................................................................24
Response Bias...................................................................................................................................................24
Sources of Bias..................................................................................................................................................24
Response Bias Exercise......................................................................................................................................24
Answers to the Types of Response Bias Exercise......................................................................................25
How Do You Control Bias?..............................................................................................................................25
Organizing and Analyzing the Collected Voices of Your Customers..........................................................................25
Affinity Diagrams.............................................................................................................................................26
Structure Trees.................................................................................................................................................27
Prioritizing Needs with Kano Analysis.............................................................................................................28
Prioritizing Needs through Customer Feedback...............................................................................................29
Working with Critical-to-Quality Requirements.......................................................................................................29
Setting Targets and Specifications for CTQs....................................................................................................30
Introduction to Quality Function Deployment................................................................................................30
Communicating the VOC Learning..........................................................................................................................31
Principles of Listening and Sharing Learning...................................................................................................31
Key Audiences..................................................................................................................................................31
Developing the Communication Plan..............................................................................................................31
Link Business/Organizational Strategy Success to CTQ Fulfillment.........................................................................32
Research Ethics..........................................................................................................................................................32
Summary...................................................................................................................................................................33
Develop Team Charter: Step 2..........................................................................................................................35
Contents....................................................................................................................................................................35
Orientation within DMAIC......................................................................................................................................35
Project Charter..........................................................................................................................................................35
Five Major Elements of a Charter..............................................................................................................................35
Business Case....................................................................................................................................................36
Seven Issues in Selecting a Project That Must Be Addressed in a Business Case......................................37
Problem and Goal Statements...........................................................................................................................37
Problem Statements.................................................................................................................................37
Goal Statements......................................................................................................................................37
SMART Problem and Goal Statements...................................................................................................38
Project Scope....................................................................................................................................................38
In/Out Frame Tool..................................................................................................................................38
Milestones........................................................................................................................................................39
Project Roles....................................................................................................................................................40
Stakeholder List......................................................................................................................................40
ARMI Model.........................................................................................................................................40
Team Roles..............................................................................................................................................41
Team Formation and the GRPI Checklist and Assessment.....................................................................42
Good versus Bad Projects..........................................................................................................................................42
Summary..................................................................................................................................................................44
Define a High-Level Process Map: Step 3..........................................................................................................45
Contents....................................................................................................................................................................45
Orientation within DMAIC......................................................................................................................................45
What Is a Process?.....................................................................................................................................................45
Elements of a Process: SIPOC....................................................................................................................................45
Levels of Processes.....................................................................................................................................................47
Categories of Processes...............................................................................................................................................48
Core Business Processes...........................................................................................................................48
Core Process Identifiers...........................................................................................................................48
Key Enabling Process..............................................................................................................................48
Process Mapping........................................................................................................................................................48
Benefits of Process Mapping.............................................................................................................................48
Perceptions of Processes....................................................................................................................................49
Build the Process Map......................................................................................................................................50
Process Mapping Steps............................................................................................................................50
Diagnosis of Systems Activity and Information Flow..............................................................................51
Build the Map.........................................................................................................................................51
Define the Boundaries of the Business Process........................................................................................52
Using the SIPOC Worksheet to Describe Business Processes..................................................................52
Validate the Process Map.........................................................................................................................54
Evaluating a Process Map.................................................................................................................................55
Impacts Resulting from the Building and Analysis of Process Maps.................................................................55
Summary...................................................................................................................................................................56
Measure Phase...........................................................................................................................................................56
SECTION II MEASURE PHASE
6 Measure Phase Overview...................................................................................................................................59
Contents....................................................................................................................................................................59
Orientation to the Measure Phase..............................................................................................................................59
Measure Phase Activity Synopsis......................................................................................................................59
Objectives..................................................................................................................................................................59
Using Statistics to Solve Problems..............................................................................................................................60
Selecting Relevant CTQ Characteristics and/or Project Ys...............................................................................61
Defining Performance Standards......................................................................................................................61
Measurement Systems Analysis..................................................................................................................................62
Using Statistics to Characterize Processes.................................................................................................................64
Measure Phase Deliverables......................................................................................................................................64
7 Select Critical-to-Quality Characteristics: Step 4.............................................................................................65
Contents....................................................................................................................................................................65
Orientation within DMAIC......................................................................................................................................65
Objectives..................................................................................................................................................................65
Quality Function Deployment..................................................................................................................................66
The QFD Opportunity .................................................................................................................................66
Formal Definition of QFD..............................................................................................................................66
Quality Function Deployment Flow................................................................................................................66
Building a House of Quality .........................................................................................................................67
Product Example: What Does Your Customer Want?..............................................................................67
Abbreviated Example of a Service-Oriented QFD Using a Different Form.......................................................73
Common QFD/House of Quality Pitfalls........................................................................................................73
Failure Modes and Effects Analysis............................................................................................................................76
FMEA Calculations.........................................................................................................................................77
Excel FMEA Tool.............................................................................................................................................78
Building an FMEA...........................................................................................................................................78
When Is an FMEA Started?....................................................................................................................78
Who Prepares an FMEA?........................................................................................................................78
Updating FMEAs....................................................................................................................................79
Data Types.................................................................................................................................................................79
Why Is Data Type Important?..........................................................................................................................80
Summary...................................................................................................................................................................81
8 Tool Training: Excel Quality Function Deployment Workbook......................................................................83
Contents....................................................................................................................................................................83
Introduction..............................................................................................................................................................83
Home Worksheet...................................................................................................................................................84
The QFD Administrative Worksheet........................................................................................................................84
QFD Stakeholder Worksheet.....................................................................................................................................86
Stakeholder Representative Worksheet.......................................................................................................................87
CTQ Initial List Worksheet.......................................................................................................................................87
Stakeholder CTQ Importance Survey Worksheet......................................................................................................87
Stakeholder CTQ Priorities Worksheet......................................................................................................................89
CTQ Priority Worksheet...........................................................................................................................................89
Process Member List Worksheet................................................................................................................................91
The Process Member List Filter.........................................................................................................................92
The Scratchpad Worksheet.........................................................................................................................................93
Process Impact Worksheets (3)...................................................................................................................................94
Assessing/Scoring Process Members Effect on CTQ Satisfaction.....................................................................96
The Process Rank Worksheets (3)..............................................................................................................................98
Summary...................................................................................................................................................................99
9 Define Performance Standards: Step 5............................................................................................................101
Contents..................................................................................................................................................................101
Orientation of Step 5 within DMAIC.....................................................................................................................101
Objectives................................................................................................................................................................101
Performance Standards............................................................................................................................................101
Purpose of Performance Standards.................................................................................................................102
Operational Definitions for Performance Standard........................................................................................103
Operational Definition Exercise...............................................................................................................................104
Tool to Use in Operational Definition Exercise..............................................................................................104
Reveiw Basic Nature of Data...................................................................................................................................104
How Discrete Data Varies from Continuous Data..........................................................................................104
Completing the Performance Standard....................................................................................................................104
Summary.................................................................................................................................................................106
10 Tool Training: 7 Process Improvement Tools..................................................................................................107
Contents..................................................................................................................................................................107
Objectives................................................................................................................................................................107
Scatter Plot Charts...................................................................................................................................................107
Build a Scatter Plot.........................................................................................................................................107
Build a Scatter Plot Chart in Excel 97-2003..........................................................................................107
Build a Scatter Plot Chart in Excel 2007...............................................................................................109
Run Charts/Control Charts.....................................................................................................................................109
Continuous Data Run/Control Charts...........................................................................................................110
Individual and Moving Range Chart.....................................................................................................110
Control Chart Formulae: Moving Range Chart....................................................................................110
Average and Range: X-Bar and R Charts...............................................................................................111
Control Chart Formulas: X-Bar and R Charts.......................................................................................111
Constructing X-Bar and R Charts.........................................................................................................112
Interpreting the X-Bar Chart.................................................................................................................112
Average and Standard Deviation Charts (X-Bar and s Charts).......................................................................113
Discrete Data Run/Control Charts.................................................................................................................114
Defect....................................................................................................................................................114
Defective...............................................................................................................................................115
Discrete Chart Selection........................................................................................................................115
Summary of Chart Selection Logic.................................................................................................................117
Checksheets.............................................................................................................................................................117
Histograms..............................................................................................................................................................117
Making a Histogram in Excel.........................................................................................................................119
Making a Histogram in Excel 97-2003..................................................................................................119
Making a Histogram in Excel 2007......................................................................................................120
Pareto Charts..................................................................................................................................................121
A Specialized Histogram: The Boxplot...........................................................................................................121
How to Make a Boxplot (Whisker) Chart.............................................................................................122
Stratification Diagrams............................................................................................................................................124
Cause-and-Effect (Fishbone/Ishikawa) Diagrams....................................................................................................126
Summary.................................................................................................................................................................128
11 Establish Data Collection Plan and Measurement System Analysis: Step 6...................................................129
Contents..................................................................................................................................................................129
Orientation within DMAIC....................................................................................................................................129
Objectives................................................................................................................................................................129
Data Collection Plan...............................................................................................................................................130
Items to Consider...........................................................................................................................................130
Pre-Data Collection Steps...............................................................................................................................131
During the Collection....................................................................................................................................131
Post-Data Collection Steps..............................................................................................................................131
Sample Data Collection Plan..........................................................................................................................131
Controlling the Measurement Environment............................................................................................................133
Sources of Measurement Environment Variation............................................................................................134
Measurement System Analysis.................................................................................................................................134
Measurement Gauge Requirements................................................................................................................134
Resolution Requirements.......................................................................................................................135
An MSA Checklist..........................................................................................................................................136
Test/Retest Study............................................................................................................................................137
Test/Retest Study Guidelines.................................................................................................................137
Test/Retest Study Example.............................................................................................................................137
Gauge Reproducibility and Repeatability Studies...........................................................................................138
GRR: Collecting the Data.....................................................................................................................138
Types ofVariation Estimated by Gauge R R.......................................................................................138
Relating R R to Your Specification Window.......................................................................................139
MSA Variance Rules of Thumb.............................................................................................................140
Gauge R R Short Form Studies...........................................................................................................140
Short Form Gauge R R Example.........................................................................................................141
Gauge R R Long Form Studies...........................................................................................................141
AIAG Long Form Gauge R R Variation Component Definitions.......................................................142
Analyzing Gauge R R with Attribute Data (AR R)....................................................................................142
Example of an Attribute R R Study.....................................................................................................142
Attribute R R Study Example Analysis................................................................................................143
Excel Attribute Gauge R R and Equipment Gauge R R Tools Provided with This Book.....................................143
Excel Attribute Gauge R R Tool...................................................................................................................144
AR R Tool Summary..........................................................................................................................145
Excel Equipment Gauge R R Tool................................................................................................................146
Working with Sample Size.....................................................................................................................146
Gauge R R: Temporal Effects.......................................................................................................................146
Summary.................................................................................................................................................................148
SECTION III ANALYZE PHASE
12 Analyze Phase Overview.................................................................................................................................153
Contents..................................................................................................................................................................153
Objectives................................................................................................................................................................153
Orientation within DMAIC....................................................................................................................................153
Step 7: Establish Process Capability.........................................................................................................................153
How Do You Determine the Performance Objective?.....................................................................................154
Step 8: Define Improvement Objective for Y...........................................................................................................154
Step 9: Identify Sources of Variation (Problems)......................................................................................................156
13 Establish Process Capability: Step 7...............................................................................................................157
Contents..................................................................................................................................................................157
Orientation within DMAIC....................................................................................................................................157
Objectives................................................................................................................................................................158
Basic Statistics Review.............................................................................................................................................159
Distributions...................................................................................................................................................159
Using Distributions to Predict Outcomes..............................................................................................159
The Normal Curve.........................................................................................................................................160
Some Statistics/Process Terms and Attributes Important to Process Improvement................................160
Normality..............................................................................................................................................160
Example of an Imperfect Normal Distribution......................................................................................161
Cumulative Normal Probability Plots....................................................................................................162
Normality and Process Improvement.....................................................................................................162
Another Example of Non-Normal Distribution.....................................................................................164
Working with Continuous Data..............................................................................................................................164
Calculating Z (Z-Score)..................................................................................................................................164
Calculating Capability....................................................................................................................................165
Calculate the Z-score for the LSL.........................................................................................................166
Calculate the Z-score for the USL.........................................................................................................166
Z-Bench.................................................................................................................................................166
Universal Equations for Long- and Short-Term Z..................................................................................167
Process Centering...........................................................................................................................................168
Rational Subgrouping.....................................................................................................................................168
Components of Variation................................................................................................................................170
Working with Discrete Data....................................................................................................................................171
Discrete Data Definitions...............................................................................................................................172
Linking DPO to the Probability of a Defect...................................................................................................172
Sigma Product Report (L-l)............................................................................................................................172
Process Yield...................................................................................................................................................175
Types of Yield........................................................................................................................................175
Can You Achieve Six Sigma through Inspections?..........................................................................................176
Quantification of Defects: Escaping Defects...................................................................................................176
Escaping Defects Exercise......................................................................................................................177
Tying It All Together...............................................................................................................................................177
Summary.................................................................................................................................................................178
14 Define Performance Objectives: Step 8...........................................................................................................179
Contents..................................................................................................................................................................179
Orientation within DMAIC....................................................................................................................................179
Objectives................................................................................................................................................................179
Defining Process Objectives.....................................................................................................................................179
Benchmarking.........................................................................................................................................................181
Nature of Benchmarking................................................................................................................................181
Types of Benchmarking..................................................................................................................................181
Benchmarking Concept versus Process...........................................................................................................182
What Benchmarking IS and ISN T................................................................................................................183
Common Benchmarking Mistakes.................................................................................................................183
Points to Remember and Questions to Ask about Benchmarking...................................................................183
Sources of Information for Benchmarking......................................................................................................186
Summary.................................................................................................................................................................186
15 Identify Sources of Variation and Waste (Problems): Step 9...........................................................................187
Contents..................................................................................................................................................................187
Orientation of the Identify Variation Sources Step within DMAIC.........................................................................187
Objectives................................................................................................................................................................187
Focus of Improvement.............................................................................................................................................188
Tools to Identify Variation Sources..........................................................................................................................188
Cause-and-Effect (Fishbone/Ishikawa) Diagram............................................................................................189
Building a Fishbone Diagram................................................................................................................189
Alternative Cause-and-Effect Exhibits............................................................................................................191
Pareto Diagrams.............................................................................................................................................192
Building a Pareto Chart.........................................................................................................................193
Process Maps..................................................................................................................................................197
Nature of Work: Value Analysis.............................................................................................................197
Process Map Analysis: Flow of Work.....................................................................................................198
Process Disconnects...............................................................................................................................198
Cycle Time Analysis.............................................................................................................................200
Process Map Analysis: Interpretation....................................................................................................200
Excel Process Map Analysis Tool.............................................................................................................................202
Value-Stream Maps.................................................................................................................................................204
Hypothesis Testing.................................................................................................................................................206
Idea of Sampling............................................................................................................................................206
Sampling Methods.........................................................................................................................................207
Statistical Hypothesis Definition...........................................................................................................207
Nature of Hypotheses...........................................................................................................................208
Hypothesis Testing Protocol.................................................................................................................208
Hypothesis: Guilty or Not Guilty?........................................................................................................209
Hypothesis Testing:/* Value..................................................................................................................210
Hypothesis Testing Types......................................................................................................................210
Types of Hypothesis Tests.....................................................................................................................210
Bridging the Real World: Relationship between oc and B.......................................................................211
Data Analysis...........................................................................................................................................................212
Studying Stability...........................................................................................................................................212
Studying Normality........................................................................................................................................213
Follow-Up Test for Non-Normal Data..................................................................................................214
Nonparametric Tests and Tools.............................................................................................................216
Working with Non-Normal Data...................................................................................................................216
Working with Normal Data: Discrete X and Continuous Y............................................................................218
^-Distribution and Small Samples...................................................................................................................221
One-Sided Use of the t-Distribution......................................................................................................221
Two-Sided Use of the t-Distribution......................................................................................................221
Conducting Tests on Variances: ANOVA................................................................................................................223
ANOVA in General........................................................................................................................................223
One-Factor ANOVA Tests..............................................................................................................................223
Two-Factor ANOVA Tests without Replication..............................................................................................224
Testing for Goodness of Fit and Independence........................................................................................................225
Chi-Square Goodness-of-Fit Tests..................................................................................................................225
Chi-Square Example..............................................................................................................................225
Chi-Square Independence Tests.....................................................................................................................226
Chi-Square Independence Test Example..............................................................................................226
Sample Size, Degrees of Freedom: Confidence Intervals.................................................................................227
Using the Confidence Interval Formula for Continuous Data to Derive Sample Size Formula......................228
Using the Confidence Interval Formula for Continuous Data to Derive Attainable Precision Given a
Maximum Sample Size..................................................................................................................................228
Three Ways to Estimate a When It Is Unknown............................................................................................229
Excel Calculator for Sample Requirements for Confidence Levels and Process Improvements.................................229
Discrete Sample Sizes......................................................................................................................................229
Confidence Interval Calculator.......................................................................................................................229
Samples Needed to Confirm Defect Factor Reductions..................................................................................229
Summary of Process and Population Sampling........................................................................................................229
Certify Process Problems.........................................................................................................................................229
Summary................................................................................................................................................................234
16 Tool Training: Change Acceptance Management...........................................................................................239
Contents..................................................................................................................................................................239
Objectives................................................................................................................................................................239
Nature of Change and Force Field Analysis.............................................................................................................239
Dilemma of Change.......................................................................................................................................240
Change Acceptance Management Methods and Techniques...................................................................................242
Creating a Shared Need..................................................................................................................................243
Assessment.............................................................................................................................................243
Strengths-Weaknesses-Opportunities-Threats (SWOT) Matrix.............................................................247
Using the Three D s to Create a Shared Need.....................................................................................247
Things to Avoid while Creating a Shared Need......................................................................................249
Shaping the Vision..........................................................................................................................................251
Making Your Vision Actionable.............................................................................................................251
Communicating Your Vision.................................................................................................................251
Mobilizing Commitment................................................................................................................................252
Building a Mobilization Communications Plan....................................................................................253
Sources of Resistance to Change............................................................................................................255
Key Constituent/Stakeholder Resistance Analysis and Conversion Plan................................................255
Key Constituent Resistance Analysis Conversion Strategy................................................................257
Changing Systems and Structures............................................................................................................................258
What Are Systems and Structures?.................................................................................................................258
What Portions of Systems and Structures Do You Want to Influence?...........................................................259
Behavioral Modification through Rewards and Censures......................................................................259
Behavioral Modification through Formal Structure and Job-Related Changes.....................................260
Internal Process of Change.....................................................................................................................................260
Summary.................................................................................................................................................................262
17 Tool Training: Project Solution Recommendation Package Tool...................................................................263
Contents..................................................................................................................................................................263
Objectives................................................................................................................................................................263
Use of the Project Solution Recommendation Package Tool...................................................................................264
Layout of the Excel Project Solution Recommendation Package Tool.....................................................................264
Using the Project Solution Recommendation Package Tool....................................................................................264
CTQ List Worksheet.....................................................................................................................................264
Solution Packages Worksheet.........................................................................................................................264
Macro Buttons on the Solution Packages Worksheet............................................................................266
Setting the Labor Rates........................................................................................................................266
Working with Solution Item Packages and Subpackages......................................................................266
Working with the Cost Projections.......................................................................................................268
Solution-CTQ Map Worksheet.....................................................................................................................268
The Options—Estimates Worksheet.................................................................................................................270
The Selected Solutions Worksheet...................................................................................................................271
Summary.................................................................................................................................................................274
SECTION IV IMPROVE PHASE
18 Improve Phase Overview.................................................................................................................................277
Contents..................................................................................................................................................................277
Orientation within DMAIC....................................................................................................................................277
Improve Phase Objectives........................................................................................................................................277
Key Points to Consider...................................................................................................................................278
Improve Phase Strategy............................................................................................................................................278
Improvement Goal..........................................................................................................................................279
Identify Vital Xs for a Given Y........................................................................................................................279
Characterization ofXs....................................................................................................................................279
Experimenting with the Process..............................................................................................................................280
Testing Theories.............................................................................................................................................280
DOE..............................................................................................................................................................280
Examples of Approaches and Solutions to Problems.......................................................................................281
Reduce Cycle Time................................................................................................................................281
Reduce Telephone Expense....................................................................................................................281
Reduce Delivery Time...........................................................................................................................281
Pilots........................................................................................................................................................................282
Pilot High-Level Steps....................................................................................................................................282
19 Experimenting and Piloting: Step 10 (Screen Potential Causes) and Step 11 (Discover
Variable Relationships)....................................................................................................................................283
Contents..................................................................................................................................................................283
Orientation within DMAIC...................................................................................................................................284
Objectives...............................................................................................................................................................284
Improvement by Design...........................................................................................................................................285
Design by Experimentation.....................................................................................................................................285
Experiment Plan.............................................................................................................................................285
Experiment Result Reports............................................................................................................................286
Experimental Strategies: Design of Experiments......................................................................................................287
Stick with a Winner .....................................................................................................................................287
One Factor at a Time (OFAT)........................................................................................................................287
Factorial Layouts, Full and Fractional.............................................................................................................287
Factors and X s.......................................................................................................................................287
High and Low Settings..........................................................................................................................287
Notations for the High- and Low-Level Settings...................................................................................287
Visualizing the Experimental Space.........................................................................................................................288
Factorial Patterns of Experimentation......................................................................................................................290
Reducing the Sizes of Experiments..........................................................................................................................290
Fractional Factoring........................................................................................................................................291
Properties of a Properly Selected Half-Fraction Factorial Design....................................................................292
Confounding..................................................................................................................................................292
Replication.....................................................................................................................................................292
Randomization: Experimenter s Insurance......................................................................................................293
Lurking Variables..................................................................................................................................294
Randomization and Lurking Variables..................................................................................................294
Using Excel to Randomize Trials (or Anything Else).............................................................................294
Running Experiments..............................................................................................................................................296
Experiment Definitions..................................................................................................................................296
Collecting the Experimental Data..................................................................................................................296
Analyzing the Experimental Data............................................................................................................................296
Factor Control Table.......................................................................................................................................297
Experimental Raw Results..............................................................................................................................297
Plotting the Raw Data...........................................................................................................................298
Plotting the Residuals............................................................................................................................298
Examine Factor Effects..................................................................................................................................304
Preparing the Worksheet to Support Main Effects and Interactions Plotting........................................304
Generating the Boxplot Charts of the Factor Effects............................................................................306
Generating a Prediction Equation/Process Transfer Function from
Your Experimental Data........................................................................................................................307
Analyzing Factor Interactions................................................................................................................310
Excel 8-Run DOE Tool...........................................................................................................................................311
Chart Worksheet Added to 8-Run DOE Tool................................................................................................314
Selectively Hide Factors.........................................................................................................................314
Boxplot Charting...................................................................................................................................314
Screening Designs....................................................................................................................................................315
Adaptation of the 8-Run DOE Tool to Run 8 Factor Plackett-Burman Analyses..........................................317
Piloting....................................................................................................................................................................320
When Should You Pilot?.................................................................................................................................321
How Should You Prepare to Pilot?..................................................................................................................321
Measure the Pilot Performance and Analyze Its Results..................................................................................321
Checking the Pilot Control Plan...........................................................................................................321
Pilot Scorecards.....................................................................................................................................321
Pilot-Information Technology (IT) Linkages..................................................................................................322
Piloting Tips and Traps..................................................................................................................................322
Summary.................................................................................................................................................................323
20 Confirming Solutions, Setting Tolerances, and Documenting: Step 12.........................................................325
Contents..................................................................................................................................................................325
Orientation within DMAIC....................................................................................................................................325
Objectives................................................................................................................................................................326
Selecting Final Experiments.....................................................................................................................................326
Detectable Effect Size..............................................................................................................................................327
Using the DES Formula...........................................................................................................................................327
Finalize Response Variables to Control....................................................................................................................327
Establishing Tolerances............................................................................................................................................328
Principles of Tolerancing.................................................................................................................................328
Tolerancing Example: A Weight-Loss Program...............................................................................................329
Tolerance Summary........................................................................................................................................330
Simulation...............................................................................................................................................................331
Why Use Simulation?.....................................................................................................................................331
When Should You Use Simulation?................................................................................................................331
Modeling and Simulation Processes................................................................................................................332
Monte Carlo Simulation..........................................................................................................................................333
Stochastic Model Example..............................................................................................................................333
Solving a Sales Forecast Problem with the Excel MC Technique...........................................................334
Portraying the Results of a MC Simulation...........................................................................................339
Deterministic Simulation.........................................................................................................................................349
Deterministic Models.....................................................................................................................................349
Building and Executing a Deterministic Model..............................................................................................349
Documentation........................................................................................................................................................349
Why Do We Document?................................................................................................................................349
Who Is the Audience for Process Documentation?.........................................................................................351
What Is Included in Process Documentation?................................................................................................351
What Formats Should Be Used for Process Documentation?..........................................................................351
Documentation Tips.......................................................................................................................................351
Summary.................................................................................................................................................................352
SECTION V CONTROL PHASE
21 Control Phase Overview..................................................................................................................................355
Contents..................................................................................................................................................................355
Orientation of Control Phase within DMAIC..........................................................................................................355
Control....................................................................................................................................................................356
Control Objectives..........................................................................................................................................356
Maintaining Control......................................................................................................................................357
What Is a Process Control System?........................................................................................................357
Key Steps to Developing a Process Control Plan....................................................................................357
Process Standardization..................................................................................................................................357
Degrees of Standardization....................................................................................................................358
Approaches to Achieving Standardization.............................................................................................359
Primary Control Mechanisms.........................................................................................................................359
Risk Management.................................................................................................................................359
Mistake Proofing...................................................................................................................................359
Statistical Process Control.....................................................................................................................359
Confirming Your Solution before Implementation...................................................................................................359
Assess the Effectiveness of Your Improvement...............................................................................................360
Make Your Improvements Permanent.....................................................................................................................360
Project Closeout......................................................................................................................................................360
22 Validate Measurement System and Confirm Solution to Management: Step 13.............................................361
Contents..................................................................................................................................................................361
Orientation within DMAIC....................................................................................................................................361
Objectives................................................................................................................................................................361
Validate and Make Provision for the Measurement System for Post-Implementation Use........................................362
Add Measurement System Training to the Organization s Technical Training...............................................363
Include Measurement Systems Acquisition, Training, and Use among the Operational Costs of the
Improved Process............................................................................................................................................363
Include Measurement and Periodic MSA in Task Assignments......................................................................364
Confirm Your Solution to Management..................................................................................................................364
CTQ Score....................................................................................................................................................364
Short-Term Sigma Improvement....................................................................................................................364
Costs and Benefits.........................................................................................................................................364
Summary.................................................................................................................................................................365
23 Build Process Control Plan: Step 14................................................................................................................367
Contents..................................................................................................................................................................367
Orientation within DMAIC....................................................................................................................................367
Objectives................................................................................................................................................................367
What Is a Quality or Control Plan?.........................................................................................................................368
Quality Plan versus Control Plan: What Is the Difference?............................................................................368
Example of Control Plan Exhibit....................................................................................................................369
Keys to Process Controls..........................................................................................................................................369
The Monitoring Process..................................................................................................................................369
Why Should You Monitor?....................................................................................................................370
What Should You Monitor?...................................................................................................................370
How Much Data Should You Collect?...................................................................................................371
How Can You Detect Changes in Your Process?.............................................................................................371
What Do You Do if You Detect a Change in Your Process?..................................................................372
What Do You Do if You Do Not Detect a Change in Your Process?.....................................................372
The Auditing Process......................................................................................................................................373
Additional Example of a Process Control Plan................................................................................................373
Risk Management....................................................................................................................................................374
Key Steps of Risk Management......................................................................................................................375
Methods to Identify Risks..............................................................................................................................375
The Elements of Risk......................................................................................................................................375
Rating Your Risks: Two Excel-Based Tools..............................................................................................................375
Risk Management Calculator for Projects and Processes................................................................................376
Risk Calculation Procedures for the Risk Calculator......................................................................................377
FMEA and Risk Mitigation Tool....................................................................................................................380
The FMEA Worksheet....................................................................................................................................380
The Mitigation Plan Action Summary...................................................................................................385
Revised Risk Scores...............................................................................................................................386
The Plan Worksheet...............................................................................................................................387
Mistake Proofing.....................................................................................................................................................387
Types of Human Error....................................................................................................................................389
Mistake Proofing Techniques.........................................................................................................................392
The Control Plan.....................................................................................................................................................392
Summary.................................................................................................................................................................393
24 Transfer Solution to Process Owner and Close Project: Step 15.................................,...................................395
Contents..................................................................................................................................................................395
Orientation within DMAIC....................................................................................................................................395
Objectives................................................................................................................................................................395
Conduct a Structured Transition....................................................................................................................396
Recommend System and Structure Modifications to Retain Your Improvements....................................................399
Turnover Briefings..................................................................................................................................................400
Training and Orientation Packages.........................................................................................................................400
Project Storyboard..................................................................................................................................................400
Project Storyboard Contents..........................................................................................................................400
Process Transfer Documentation.............................................................................................................................403
SPC Recommendations..........................................................................................................................................404
Selecting Appropriate Charts.........................................................................................................................404
Closing Your Project................................................................................................................................................405
Administrative Tasks......................................................................................................................................405
Implementation Summary.............................................................................................................................406
Lessons Learned..............................................................................................................................................407
Formatted Lessons Learned Document................................................................................................408
IT-Specific Tasks (When Appropriate)...........................................................................................................408
Project Wrap-Up Summary Document..........................................................................................................411
Summary.................................................................................................................................................................412
Appendix 1: Accompanying Compact Disk Contents..............................................................................................413
Appendix 2: Glossary...............................................................................................................................................419
Appendix 3: Acronyms and Abbreviations...............................................................................................................427
Appendix 4: DMAIC Project Guidelines and Checklists.........................................................................................429
Appendix 5: Example of a Lessons Learned Form Filled Out by a Team Member...............................................443
Appendix 6: Example of an Administrative Closing Document..............................................................................447
Appendix 7: DPMO to Sigma Conversion Table......................................................................................................449
Appendix 8: Distribution Tables..............................................................................................................................451
Index........................................................................................................................................................................463
|
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| spelling | Carroll, Charles T. Verfasser aut Six Sigma for powerful improvement a green belt DMAIC training system with software tools and a 25-lesson course Charles T. Carroll Boca Raton, Fla. [u.a.] CRC Press 2013 XLIX, 473 S. Ill., graph. Darst. 1 CD-ROM (12 cm) txt rdacontent n rdamedia nc rdacarrier "The book follows Six Sigma's Define-Measure-Analyze-Improve-Control (DMAIC) procedures and tools. It will provide you with reasons for using the tools, underlying doctrine, and the formulas and steps, themselves"-- Provided by publisher. Includes bibliographical references and index Wirtschaft Six sigma (Quality control standard) Textbooks BUSINESS & ECONOMICS / General bisacsh TECHNOLOGY & ENGINEERING / Manufacturing bisacsh TECHNOLOGY & ENGINEERING / Quality Control bisacsh http://images.tandf.co.uk/common/jackets/websmall/978146656/9781466564695.jpg Cover image HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=026058304&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Carroll, Charles T. Six Sigma for powerful improvement a green belt DMAIC training system with software tools and a 25-lesson course Wirtschaft Six sigma (Quality control standard) Textbooks BUSINESS & ECONOMICS / General bisacsh TECHNOLOGY & ENGINEERING / Manufacturing bisacsh TECHNOLOGY & ENGINEERING / Quality Control bisacsh |
| title | Six Sigma for powerful improvement a green belt DMAIC training system with software tools and a 25-lesson course |
| title_auth | Six Sigma for powerful improvement a green belt DMAIC training system with software tools and a 25-lesson course |
| title_exact_search | Six Sigma for powerful improvement a green belt DMAIC training system with software tools and a 25-lesson course |
| title_full | Six Sigma for powerful improvement a green belt DMAIC training system with software tools and a 25-lesson course Charles T. Carroll |
| title_fullStr | Six Sigma for powerful improvement a green belt DMAIC training system with software tools and a 25-lesson course Charles T. Carroll |
| title_full_unstemmed | Six Sigma for powerful improvement a green belt DMAIC training system with software tools and a 25-lesson course Charles T. Carroll |
| title_short | Six Sigma for powerful improvement |
| title_sort | six sigma for powerful improvement a green belt dmaic training system with software tools and a 25 lesson course |
| title_sub | a green belt DMAIC training system with software tools and a 25-lesson course |
| topic | Wirtschaft Six sigma (Quality control standard) Textbooks BUSINESS & ECONOMICS / General bisacsh TECHNOLOGY & ENGINEERING / Manufacturing bisacsh TECHNOLOGY & ENGINEERING / Quality Control bisacsh |
| topic_facet | Wirtschaft Six sigma (Quality control standard) Textbooks BUSINESS & ECONOMICS / General TECHNOLOGY & ENGINEERING / Manufacturing TECHNOLOGY & ENGINEERING / Quality Control |
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