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Treasure Chest of Six Sigma Growth Methods, Tools, and Best Practices

By Lynne Hambleton

Published by Prentice Hall

Published Date: May 25, 2011

Description

This reference is the first comprehensive how-to collection of Six Sigma tools, methodologies, and best practices. Leading implementer Lynne Hambleton covers the entire Six Sigma toolset, including more than 70 different tools—ranging from rigorous statistical and quantitative tools, to “softer” techniques. The toolset is organized in an easy-to-use, alphabetical encyclopedia and helps professionals quickly select the right tool, at the right time for every business challenge.

Hambleton systematically discusses which questions each tool is designed to answer; how the tool compares with similar tools; when to use it; how to use it step-by-step; how to analyze and apply the output; and which other tool to use with it. To further illustrate and clarify tool usage, she presents hundreds of figures, along with never-before-published hints, tips, and real-world, “out-of-the-box” examples.  

 

Coverage includes

 

·         Real-world guidance to help practitioners raise the most important questions and determine the best resolution

·         Statistical techniques, including ANOVA, multi-vari charts, Monte Carlo simulations, normal probability plots, and regression analysis

·         Benchmarks, capability and cost/benefit analyses, Porter’s Five Forces, scorecards, stakeholder analysis, and brainstorming techniques

·         CPM, CTQ, FMEA, HOQ, and GOSPA

·         GANTT, PERT chart, and other Six Sigma project management tools

·         7QC: cause and effect diagrams, checklists, control charts, fishbone diagram, flowchart, histogram, Pareto chart, process maps, run chart, scatter diagram, and the stratification tool

·         7M: AND, affinity diagrams, interrelationship diagrams, matrix diagrams, prioritization matrices, PDPC, and tree diagrams

·         Crystal Ball, Minitab, and Quality Companion 2 software to facilitate the use of statistical and analytical tools and more to help you become a more effective Six Sigma practitioner

·         This book is also available in a highly-searchable eBook format at www.prenhallprofessional.com/title/0136007376 and other online booksellers,.

 

To provide crucial context, Hambleton illuminates four leading methodologies: DMAIC, Lean Six Sigma, Design for Six Sigma, and Six Sigma for Marketing. She also presents ten electronic articles that are available for download at www.prehallprofessional.com. The articles cover proven Six Sigma best practices for accelerating growth and increasing profitability, including techniques for product development, commercialization, portfolio design, benchmark implementation, project management, and collection of customer requirements.

 

 

From start to finish, this bookdelivers fast, thorough and reliable answers—knowledge you’ll rely on in every Six Sigma project, for years to come.

 

Preface

Introduction       Different Methods for Different Purposes

Part I   Six Sigma Methodology Overview: Choosing the Right Approach to Address the Requirements

Section 1           Define-Measure-Analyze-Improve-Control (DMAIC)

Section 2           Lean and Lean Six Sigma

Section 3           Design for Six Sigma (DFSS)

Section 4           Six Sigma for Marketing (SSFM)

Part II Six Sigma Tools and Techniques: Choosing the Right Tool to Answer the Right Question at the Right Time

Encyclopedia     The Six Sigma Encyclopedia of Business Tools and Techniques

Summary Tool Matrix

A         Activity Network Diagram (AND) - 7M Tool

Affinity Diagram - 7M Tool

Analysis of Variance (ANOVA)

Arrow Diagram

B         Benchmarking

Box Plots[md]Graphical Tool

Brainstorming Technique

C         Capability Analysis

Cause and Effect Diagram - 7QC Tool

Cause and Effect Prioritization Matrix

Cause and Prevention Diagram

Checklists - 7QC Tool

Communication Plan

Conjoint Analysis

Control Charts - 7QC Tool

Control Plan

Cost / Benefit Analysis

Critical Path Method (CPM)

Critical-to-Quality (CTQ)

D         Data Collection Matrix

Design of Experiment (DOE)

Dotplot

F          Failure Modes and Effects Analysis (FMEA)

5-Whys

Fault Tree Analysis

Fishbone Diagram - 7QC Tool

Flowchart - 7QC Tool

G         Gantt Chart

GOSPA (Goals, Objectives, Strategies, Plans and Actions)

Graphical Methods

H         Histogram - 7QC Tool

House of Quality (HOQ)

Hypothesis Testing

I           Interrelationship Diagram - 7M Tool

K         KJ Analysis

L          Launch (or Transition) Plan

M        Market Perceived Quality Profile (MPQP)

Matrix Diagrams -7M Tool

Measurement System Analysis (MSA)

Multi-Vari Chart

Monte Carlo Simulation 

N         Normal Probability Plot

P          Pareto Chart - 7QC Tool

PERT Chart

Poka-Yoke

Porter's 5 Forces

Prioritization Matrices - 7M Tool

Process Capability Analysis

Process Decision Program Charts (PDPC) - 7M Tool

Process Map (or Flowchart) - 7QC Tool

Project Charter

Pugh Concept Evaluation

Q         Quality Function Deployment (QFD)

 R        RACI Matrix (Responsible, Accountable, Consulted, Informed)    12

Real-Win-Worth (RWW) Analysis

Regression Analysis

Risk Mitigation Plan

Rolled Throughput Yield

Run Chart - 7QC Tool

S          7M - Seven Management Tool

7QC - Seven Quality Control Tool

Sampling           4

Scatter Diagram - 7QC Tool

Scorecards

SIPOC (Supplier-Input-Process-Output-Customer)

SMART Problem & Goal Statements for a Project Charter

Solution Selection Matrix

Stakeholder Analysis

Statistical Tools

Stratification - 7QC Tool

SWOT (Strengths-Weaknesses-Opportunities-Threats)

T          Tree Diagram - 7M Tool

TRIZ

V          Value Stream Analysis

Voice of Customer Gathering Techniques

W         Work Breakdown Structure (WBS)

Y          Y = f (X)

Part III            Best Practices Articles (Available for download when you register your book at www.informit.com)

The Anatomy of Quality Loss in a Product

The Anatomy of Variations in Product Performance

Benchmarking — Avoid Arrogance and Lethargy

Building Strength via Communities of Practice and Project Management

Discovery-Based Learning

Lean Six Sigma for Fast Track Commercialization High Risk-High Reward, Rapid Commercialization: PROCEED WITH CAUTION!

Listening to the Customer First-Hand; Engineers Too

The Practice of Designing Relationships

A Process for Product Development

Selecting Project Portfolios using Monte Carlo Simulation and Optimization

 Part IV           Appendixes

Appendix A      Statistical Distribution Tables

Appendix B       Glossary

Appendix C       References

Index

Table of Contents

Preface .......................................................................................................xv

Introduction Different Methods for Different Purposes..................1

Part I Six Sigma Methodology Overview: Choosing the Right

Approach to Address the Requirements

Section 1 Define-Measure-Analyze-Improve-Control (DMAIC)....13

Section 2 Lean and Lean Six Sigma ....................................................29

Section 3 Design for Six Sigma (DFSS)...............................................45

Section 4 Six Sigma for Marketing (SSFM) ........................................67

Part II Six Sigma Tools and Techniques: Choosing the Right

Tool to Answer the Right Question at the Right Time

The Six Sigma Encyclopedia of Business Tools and Techniques .....115

Summary Tool Matrix............................................................................115

A Activity Network Diagram (AND) - 7M Tool . . . . . . . . . . . . . 127

Affinity Diagram - 7M Tool..........................................................136

Analysis of Variance (ANOVA)...................................................142

Arrow Diagram..............................................................................159

B Benchmarking................................................................................160

Box Plots–Graphical Tool ...........................................................165

Brainstorming Technique .............................................................168

C Capability Analysis .......................................................................173

Cause-and-Effect Diagram - 7QC Tool .......................................173

Cause-and-Effect Prioritization Matrix ......................................188

Cause and Prevention Diagram ..................................................198

Checklists - 7QC Tool....................................................................204

Conjoint Analysis ..........................................................................207

Control Charts - 7QC Tool............................................................217

Cost/Benefit Analysis...................................................................238

Critical Path Method (CPM) ........................................................242

Critical-to-Quality (CTQ) .............................................................242

D Data Collection Matrix..................................................................248

Design of Experiment (DOE).......................................................250

Dotplot ............................................................................................280

F Failure Modes and Effects Analysis (FMEA).............................287

5-Whys ............................................................................................305

Fault Tree Analysis (FTA).............................................................309

Fishbone Diagram - 7QC Tool .....................................................316

Flowchart - 7QC Tool ....................................................................316

G Gantt Chart.....................................................................................317

GOSPA (Goals, Objectives, Strategies, Plans and Actions)......320

Graphical Methods........................................................................323

H Histogram - 7QC Tool...................................................................330

House of Quality (HOQ) ..............................................................335

Hypothesis Testing........................................................................335

I Interrelationship Diagram - 7M Tool..........................................369

K KJ Analysis .....................................................................................375

M Market Perceived Quality Profile (MPQP) ................................390

Matrix Diagrams - 7M Tool..........................................................399

Measurement System Analysis (MSA).......................................412

Monte Carlo Simulation ...............................................................431

Multi-vari Chart.............................................................................439

N Normal Probability Plot ...............................................................444

P Pareto Chart - 7QC Tool................................................................445

PERT (Program Evaluation and Review Technique) Chart ....453

Poka-Yoke .......................................................................................462

Porter’s 5 Forces ............................................................................464

Prioritization Matrices - 7M Tool ................................................470

Process Capability Analysis.........................................................486

Process Decision Program Charts (PDPC) - 7M Tool ...............515

Process Map (or Flowchart) - 7QC Tool .....................................522

Pugh Concept Evaluation and Selection....................................534

Q Quality Function Deployment (QFD).........................................543

Treasure Chest of Six Sigma Growth Methods, Tools vi ols & Best Practices

00 0132300214_fm.qxd 6/27/07 12:10 PM Page vi

R RACI Matrix (Responsible, Accountable, Consulted,

Informed)........................................................................................554

Real-Win-Worth (RWW) Analysis...............................................560

Regression Analysis ......................................................................571

Risk Mitigation Plan......................................................................601

Rolled Throughput Yield..............................................................610

Run Chart - 7QC Tool....................................................................611

S 7M - Seven Management Tool .....................................................615

7QC - Seven Quality Control Tool...............................................616

Sampling.........................................................................................618

Scatter Diagram - 7QC Tool .........................................................640

Scorecards.......................................................................................653

SIPOC (Supplier-Input-Process-Output-Customer).................663

SMART Problem & Goal Statements for a Project Charter .....665

Solution Selection Matrix .............................................................672

Stakeholder Analysis ....................................................................681

Statistical Tools...............................................................................684

Stratification - 7QC Tool ...............................................................697

SWOT (Strengths-Weaknesses-Opportunities-Threats)...........699

T Tree Diagram - 7M Tool ................................................................712

TRIZ.................................................................................................715

V Value Stream Analysis ..................................................................727

Voice of Customer Gathering Techniques..................................737

W Work Breakdown Structure (WBS) .............................................753

Y Y = f (X) ...........................................................................................758

Part III Best Practices Articles

The Anatomy of Quality Loss in a Product ...............................PDF:763

The Anatomy of Variations in Product Performance ...............PDF:777

Benchmarking–Avoid Arrogance and Lethargy.....................PDF:789

Building Strength via Communities of Practice and Project

Management...................................................................................PDF:799

Complex Organizational Change Through Discovery-based

Learning .........................................................................................PDF:827

Lean Six Sigma for Fast Track Commercialization

High Risk-High Reward, Rapid Commercialization:

PROCEED WITH CAUTION! .....................................................PDF:835

Listening to the Customer First-Hand; Engineers Too ............PDF:851

The Practice of Designing Relationships....................................PDF:873

A Process for Product Development...........................................PDF:887

Selecting Project Portfolios using Monte Carlo Simulation and

Optimization ..................................................................................PDF:921

Part IV Appendixes

Appendix A Statistical Distribution Tables...................................939

Appendix B Glossary.......................................................................951

Appendix C References ...................................................................979

Index ........................................................................................................981

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ISBN-13: 978-0-13-279947-8

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