Six Sigma+Lean Toolset: Executing Improvement Projects Successfully Book

Introduction 3

The Formula for Success 5

Quality as Success Factor 7

Acceptance as Success Factor 18

Management Commitment as Success Factor 23

Result: Measurable, Sustainable Success 26

Define 27

Project Charter 30

SIPOC 34

Customer Orientation 36

Research Methods for Collecting Customer Needs 37

Customer Voice Chart 38

Kano Model 39

Tool 1: CTQ Matrix 42

Tool 1: CTB Matrix 44

Stakeholder Analysis 46

Kick-Off Meeting 48

Gate Review 50

Checklist for the Define Phase 52

Measure 53

Tool 2: Measurement Matrix 56

Data Collection Plan 58

Operational Definition 60

Data Sources and Type 63

Sampling Strategy 65

Data Collection Forms 69

Measurement System Analysis 71

Gage R&R for Discrete (Binary) Data 74

Gage R&R ANOVA for Continuous Data 76

Variation 79

Graphs and Charts 80

Location and Spread Parameters 95

Process Capability Calculation 102

Checklist for the Measure Phase 119

Analyze 121

Cause & Effect Diagram 124

FMEA 126

Process Mapping 132

Interface Analysis 136

Spaghetti Diagram 138

Value Analysis 140

Time Analysis 143

Value Stream Map 145

The Importance of Speed 149

Identifying Process Constraints 152

Tool 3: Input-Process Measurement Matrix 154

Data Stratification 156

Transforming Data 158

Hypothesis Testing 161

ANOVA 168

Correlation 176

Linear Regression 178

DOE - Design of Experiments 185

Analyze Closure Matrix 200

Checklist for the Analyze Phase 201

Improve 203

Theory of Constraints - TOC 206

5 S 208

Setup Time Reduction 211

Generic Pull System 214

Replenishment Pull System 217

Poka Yoke 222

Total Productive Maintenance - TPM 225

Lean forService 229

Creativity Techniques 232

Tools for Selecting Solutions 241

Implementation Planning 252

Pilot Program 262

Roll Out 264

Checklist for the Improve Phase 265

Control 267

Process Documentation 270

Monitoring/Visual Process Monitoring and Control 272

Monitoring/Control Charts 274

Reaction Plan 283

Checklist for the Control Phase 285

Project Documentation 286

Project Closure 288

Kaizen DMAIC 289

Appendix

Abbreviations 293

Index 296

Sigma Value Table 315