The Six Sigma handbook: [a complete guide for green belts, black belts, and managers at all levels]
Gespeichert in:
| Hauptverfasser: | , |
|---|---|
| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
New York
McGraw-Hill Education
[2018]
|
| Ausgabe: | Fifth edition |
| Schlagworte: | |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | Literaturverz. S. 667 - 674 |
| Beschreibung: | xiv, 706 Seiten Diagramme |
| ISBN: | 9781260121827 1260121828 |
Internformat
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Datensatz im Suchindex
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| adam_text | CONTENTS Preface..................................................................................................... .xiii PART I Six Sigma Implementation and Management CHAPTER 1 Building the Responsive Six Sigma Organization..................................3 What Is Six Sigma?......................................................................................... 3 Why Six Sigma?...................................................................................... 4 The Six Sigma Philosophy..................................................................... 6 Six Sigma Versus Traditional Three Sigma Performance.................... 8 The Change Imperative.......................................................................12 Implementing Six Sigma............................................................................. 17 Timetable....................... 18 Infrastructure....................................................................................... 21 Integrating Six Sigma and Related Initiatives....................................38 Deployment to the Supply Chain....................................................... 52 Communications and Awareness....................................................... 54 CHAPTER 2 Recognizing and Capitalizing on Opportunity................................... 61 Methods for Collecting Customer Data................................................... 61 Surveys................................................................................................. 62 Focus
Groups....................................................... 71 Operational Feedback Systems........................................................... 72 Cost of Poor Quality................................................................................... 75 Cost of Quality Examples................................................................... 78 Quality Cost Bases............................................................................... 81 Benchmarking............................................................................................... 82 The Benchmarking Process .................................................................. 82 Getting Started with Benchmarking................................................... 83 Why Benchmarking Efforts Fail......................................................... 85 The Benefits ofBenchmarking ............................................................86 v
vi I Contents Some Dangers of Benchmarking........................................................... 8 Innovation........................................................................................................88 Kano Model.......................................................................................... Quality Function Deployment............................................................. 89 Translating Customer Demands........................................................... 93 Creative Destruction............................................................................ 101 Strategic Planning.......................................................................................... 106 Organizational Vision.......................................................................... ^θ? Strategy Development.......................................................................... ^θ9 Strategic Styles...................................................................................... HO Possibilities-Based Strategic Decisions............................................... Hl Strategic Development Using Constraint Theory................................... 113 The Systems Approach ........................................................................ H4 Basic Constraint Management Principles and Concepts................ 117 Tools of Constraint Management ................................................... 126 Constraint Management Measurements ......................................... 138 Summary and
Conclusion.................................................................. 143 CHAPTER 3 Data-Driven Management......................................................................... 145 Attributes of Good Metrics.......................................................................... 145 Measuring Causes and Effects............................................................147 The Balanced Scorecard................................................................................ 149 Translating the Vision.......................................................................... 151 Communicating and Linking............................................................. 159 Business Planning................................................................................ 162 Feedback and Learning........................................................................ 166 CHAPTER 4 Maximizing Resources................................................................................ 177 Choosing the Right Projects........................................................................ 177 Types of Projects................................ 178 Analyzing Project Candidates..............................................................179 Using Pareto Analysis to Identify Six Sigma Project Candidates . 187 Throughput-Based Project Selection..................................................189 Ongoing Management Support................................................................. 195 Internal Roadblocks................................................................ 196
External Roadblocks................. լ97 Individual Barriers to Change................................. I97
Contents Į vii Ineffective Management Support Strategies..................................... 198 Effective Management Support Strategies....................................... 199 Cross-Functional Collaboration....................................................... 200 Tracking Six Sigma Project Results......................................................... 201 Financial Results Validation............................................................. 204 Team Performance Evaluation......................................................... 204 Team Recognition and Reward.........................................................205 Lessons-Learned Capture and Replication..................................... 207 PART II Six Sigma Tools and Techniques CHAPTER 5 Project Management Using DMAIC and DMADV........................... 211 DMAIC and DMADV Deployment Models........................................... 211 Project Scheduling......................................... 216 Project Reporting.................. 228 Project Budgets........... . .................................................................... 230 Project Records............................. 231 Six Sigma Teams............................... 232 Team Membership............................................................................. 233 Team Dynamics Management, Including Conflict Resolution ... 233 Stages in Group Development........................................................... 234 Member Roles and Responsibilities................................................. 236 Managements Role ......
............................... 238 Facilitation Techniques..................................................................... 238 CHAPTER 6 The Define Phase .................................................................................... 243 Project Charters......................................................................................... 243 Project Decomposition............................................................................. 246 Work Breakdown Structures ........................................................... 246 Pareto Analysis ................................................................................. 247 Deliverables............................ 248 Critical to Quality Metrics............................................................... 250 Critical to Schedule Metrics............................................................. 257 Critical to Cost Metrics..................................... 259 Top-Level Process Definition................................................................... 265 Process Maps..................................................................................... 266 Assembling the Team.................................................................................267
viii I Contents CHAPTER 7 The Measure Phase.................................................................................... Process Definition....................................................................................... 26$ Flowcharts........................................................................................... 270 SIPOC.................................................................................................. 271 Metric Definition......................................................................................... 275 Measurement Scales...................... 276 Discrete and Continuous Data...........................................................278 Process Baseline Estimates.........................................................................278 Enumerative and Analytic Studies.................................................... 280 Principles of Statistical Process Control.............................................283 Estimating Process Baselines Using Process Capability Analysis.. 289 CHAPTERS Process Behavior Charts..........................................................................291 Distributions................................................................................................ 291 Methods ofEnumeration.................................................................... 291 Frequency and Cumulative Distributions........................................ 293 Sampling Distributions...................................................................... 294 Binomial
Distribution........................................................................ 295 Poisson Distribution.......................................................................... 297 Hypergeometric Distribution........................................................... 298 Normal Distribution......................................................................... 299 Lognormal Distribution................................................................... 306 Exponential Distribution..................................................................307 Weibull Distribution................ ......................................................... 309 Control Charts for Variables Data............................................................ 310 Averages and Ranges Control Charts................................................ 310 Averages and Standard Deviation (Sigma) Control Charts.......... 314 Control Charts for Individual Measurements (X Charts)............ 317 Control Charts for Attributes Data ........................................................... 323 Control Charts for Proportion (p Charts).........................................323 Control Charts for Count of Items fnp Charts).............................. 327 Control Charts for Average Occurrences-Per-Unit fu Charts) ... 329 Control Charts for Counts of Occurrences-Per-Unit fc Charts) .. 332 Control Chart Selection.......... .................................................................... 33g Rational Subgroup Sampling...................................................... 336 Control Chart
Interpretation.............................................................. 341 Run Tests.................................................................... 347
Contents I ix Short-Run Statistical Process Control Techniques..............................348 Variables Data.................................................................................. 350 Attribute SPCfor Small and Short Runs........................................ 361 Summary of Short-Run SPC............................................................ 368 SPC Techniques for Automated Manufacturing..................................369 Problems with Traditional SPC Techniques.................................. 369 Special and Common Cause Charts............................................... 370 EWMA Common Cause Charts..................................................... 371 EWMA Control Charts Versus Individuals Charts...................... 378 Process Capability Indices....................................................................... 380 Example ofNon-Normal Capability AnalysisUsing Minitab.... 385 CHAPTER 9 Measurement Systems Evaluation...................................................... 391 Definitions.................................................................................................. 391 Measurement System Discrimination........................................... 395 Stability............................................................................................. 395 Bias.................................................................................................... 396 Repeatability..................................................................................... 397
Reproducibility................................................................................. 400 Part-to-Part Variation..................................................................... 403 Summary Reporting........................................................................ 403 Gage R R Analysis Using Minitab............................................... 404 Linearity............................................................................................ 407 Linearity Analysis Using Minitab................................................... 409 Attribute Measurement Error Analysis................................................. 410 Operational Definitions................................................................... 412 How to Conduct Attribute Inspection Studies................................ 413 Minitab Attribute Gage R R Example......................................... 417 CHAPTER 10 Analyze Phase.......................................................................................... 423 Value Stream Analysis.............................................................................. 423 Value Stream Mapping.................................................................... 427 Spaghetti Charts................................................................................ 433 Analyzing the Sources of Variation....................................................... 434 Cause and Effect Diagrams............................................................. 435
Boxplots.............................................................................................. 437 Statistical Inference......................................................................... 439
x I Contents Chi-Square, Students t, and f Distributions.....................................440 Point and Interval Estimation.......................................................... 444 Hypothesis Testing............................................................................... 452 Resampling (Bootstrapping)............................................................... 459 Regression and Correlation Analysis.........................................................460 Linear Models....................................................................................... 463 Least-Squares Fit................................................................................. 466 Correlation Analysis........................................................................... 470 Designed Experiments................................................................................. 472 The Traditional Approach Versus Statistically Designed Experiments.............................................. 472 Terminology.........................................................................................472 Design Characteristics........................................................................ 474 Types of Design.....................................................................................475 One-Factor ANOVA.......................................................................... 477 Two-Way ANOVA with No Replicates.............................................. 479 Two- Way ANOVA with Replicates.................................................... 480 Full and
Fractional Factorial............................................................ 482 Power and Sample Size...................................................................... 491 Testing Common Assumptions.......................................................... 492 Analysis of Categorical Data...................................................................... 499 Making Comparisons Using Chi-Square Tests................................ 499 Logistic Regression.............................................................................. 501 Binary Logistic Regression.................................................................. 503 Ordinal Logistic Regression................................................................506 Nominal Logistic Regression............................................................. 510 Non-Parametric Methods......................................................................... 513 CHAPTER 11 The Improve/Design Phase..................................................................... 517 Using Customer Demands to Make Design and Improvement Decisions.................................................... 517 Pugh Concept Selection Method........................................................ 517 Lean Techniques for Optimizing Flow.................................................... 518 Unnecessary Process Steps.................................................................. 519 Excessive Movement ofMaterial or Personnel................................ 519 Bottleneck or
Constraint.................................................................... 520 Process Errors Requiring Rework...................................................... 521 Excess In-process Inventory................................................................ 521
Contents I xi Understanding Queues to Balance Processes................................... 526 Using Empirical Model Building to Optimize....................................... 529 Phase 0: Getting Your Bearings....................................................... 531 Phase I: The Screening Experiment................................................. 532 Phase П: Steepest Ascent (Descent) ........................... 536 Phase III: The Factorial Experiment............................................... 538 Phase IV: The Composite Design..................................................... 540 Phase V: Robust Product and Process Design................................. 544 Data Mining, Artificial Neural Networks, and Virtual Process Mapping.................................................... 548 Example of Neural Net Models. ................................................... 549 Optimization Using Simulation............................................................... 552 Predicting CTQ Performance............................................... 552 Simulation Tools........................................... 553 Random Number Generators........................................................... 557 Model Development........................................................................... 560 Virtual DOE Using Simulation Software......................................... 570 Risk Assessment Tools............................................................................... 572 Design Review...................................................................................
573 Fault-Tree Analysis........................................................................... 574 Safety Analysis..................... 575 Failure Mode and Effect Analysis..................................................... 578 Defining New Performance Standards Using Statistical Tolerancing. 581 Assumptions of Formula................................................................... 585 Tolerance Intervals............................................................................. 585 CHAPTER 12 Control/Verify Phase...............................................................................587 Validating the New Process or Product Design..................................... 587 Business Process Control Planning......................................................... 588 Maintaining Gains............................................................................. 588 Tools and Techniques Useful for Control Planning..........................590 Preparing the Process Control Plan................................................. 591 Process Control Planningfor Short and Small Runs................ . . 593 Process Audits..................................................................................... 596 Selecting Process Control Elements................................................. 596 Other Elements of the Process Control Plan................................... 599 Multivariate Control Charts..................................................................... 599 Principal Component Analysis.................................................................
608
xii I Contents APPENDIX 1 Glossary of Basic Statistical Terms....................................................... APPENDIX 2 Area Under the Standard Normal Curve............................................. 623 APPENDIX 3 Critical Values of the ř-Distribution...................................................... 627 APPENDIX 4 Chi-Square Distribution.......................................................................... 629 APPENDIX 5 F Distribution (a = APPENDIX 6 F Distribution (a = 5%)............................................................................................... 633 APPENDIX 7 Poisson Probability Sums.......................................................................... 635 APPENDIX 8 Tolerance Interval Factors.......................................................................... 639 APPENDIX 9 Control Chart Constants............................................................................ 643 APPENDIX 10 Control Chart Equations............................ APPENDIX 11 Table of d2* Values........................................................................................ 647 APPENDIX 12 Factors for Short Run Control Charts for Individuals, X, and R Charts........................................................................................... 649 APPENDIX 13 Sample Customer Survey............................................................................ 651 APPENDIX 14 Process σ Levels and Equivalent PPM Quality Levels.......................... 653 APPENDIX 15 Black Belt Effectiveness
Certification...................................................... 655 APPENDIX 16 Green Belt Effectiveness Certification.................................................... 667 APPENDIX 17 AHP Using Microsoft Excel......................................................................... 679 1%).............................................................................. 631 645 Notes..................................................................................................................................... 683 References............................................................................. gg5 Index..................................................................................................................................... 693
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| spelling | Pyzdek, Thomas 1948- Verfasser (DE-588)1133380735 aut The Six Sigma handbook [a complete guide for green belts, black belts, and managers at all levels] Thomas Pyzdek, Paul Keller Fifth edition New York McGraw-Hill Education [2018] xiv, 706 Seiten Diagramme txt rdacontent n rdamedia nc rdacarrier Literaturverz. S. 667 - 674 Production management / Handbooks, manuals, etc Quality control / Statistical methods / Handbooks, manuals, etc Six sigma (Quality control standard) Estatística (controle de qualidade;métodos) larpcal Production management Handbooks, manuals, etc Quality control Statistical methods Handbooks, manuals, etc Six sigma (Quality control standard) Handbooks, manuals, etc Qualitätsmanagement (DE-588)4219057-5 gnd rswk-swf Six Sigma (DE-588)7604241-8 gnd rswk-swf Qualitätsmanagement (DE-588)4219057-5 s DE-604 Six Sigma (DE-588)7604241-8 s Keller, Paul Verfasser (DE-588)143609920 aut Digitalisierung UB Bamberg - ADAM Catalogue Enrichment application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=030682768&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Pyzdek, Thomas 1948- Keller, Paul The Six Sigma handbook [a complete guide for green belts, black belts, and managers at all levels] Production management / Handbooks, manuals, etc Quality control / Statistical methods / Handbooks, manuals, etc Six sigma (Quality control standard) Estatística (controle de qualidade;métodos) larpcal Production management Handbooks, manuals, etc Quality control Statistical methods Handbooks, manuals, etc Six sigma (Quality control standard) Handbooks, manuals, etc Qualitätsmanagement (DE-588)4219057-5 gnd Six Sigma (DE-588)7604241-8 gnd |
| subject_GND | (DE-588)4219057-5 (DE-588)7604241-8 |
| title | The Six Sigma handbook [a complete guide for green belts, black belts, and managers at all levels] |
| title_auth | The Six Sigma handbook [a complete guide for green belts, black belts, and managers at all levels] |
| title_exact_search | The Six Sigma handbook [a complete guide for green belts, black belts, and managers at all levels] |
| title_full | The Six Sigma handbook [a complete guide for green belts, black belts, and managers at all levels] Thomas Pyzdek, Paul Keller |
| title_fullStr | The Six Sigma handbook [a complete guide for green belts, black belts, and managers at all levels] Thomas Pyzdek, Paul Keller |
| title_full_unstemmed | The Six Sigma handbook [a complete guide for green belts, black belts, and managers at all levels] Thomas Pyzdek, Paul Keller |
| title_short | The Six Sigma handbook |
| title_sort | the six sigma handbook a complete guide for green belts black belts and managers at all levels |
| title_sub | [a complete guide for green belts, black belts, and managers at all levels] |
| topic | Production management / Handbooks, manuals, etc Quality control / Statistical methods / Handbooks, manuals, etc Six sigma (Quality control standard) Estatística (controle de qualidade;métodos) larpcal Production management Handbooks, manuals, etc Quality control Statistical methods Handbooks, manuals, etc Six sigma (Quality control standard) Handbooks, manuals, etc Qualitätsmanagement (DE-588)4219057-5 gnd Six Sigma (DE-588)7604241-8 gnd |
| topic_facet | Production management / Handbooks, manuals, etc Quality control / Statistical methods / Handbooks, manuals, etc Six sigma (Quality control standard) Estatística (controle de qualidade;métodos) Production management Handbooks, manuals, etc Quality control Statistical methods Handbooks, manuals, etc Six sigma (Quality control standard) Handbooks, manuals, etc Qualitätsmanagement Six Sigma |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=030682768&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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