Process Improvement Using Six Sigma

Rama Shankar

Description

In order to stay competitive, organizations need to continuously improve their processes. The purpose of this book is to provide the practitioner with the necessary tools and techniques with which to implement a systematic approach to process improvement initiatives using the Six Sigma methodology.
While there are many self-help books out there, here the topics are discussed in a way so as to remove the fear out of Six Sigma and statistics. This guide takes readers through the five phases of the Six Sigma methodology, Define-Measure-Analyze-Improve-Control (DMAIC), in five clearly written and easy-to-understand sections. You learn each phase’s purpose and what activities to perform in each. Numerous examples are included throughout and all statistics are described to the exact level of understanding necessary. Each of the five sections then concludes with a checklist to ensure that all of the phase’s activities have been completed.
Following the systematic approach outlined in this book will ensure that customer needs and functional area needs are understood and met; knowledge of subject matter experts (SMEs) and team members to improve the process is leveraged; team consensus is reached on the root cause(s) for problems; and risk is managed by addressing all compliance issues.
Author Webinar Series:
"https://asq.webex.com/asq/lsr.php?RCID=57f5326bc0d05d791507f1b6ad92f99d" as the author provides a thorough introduction to this book and its key deliverables.

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Gestion et management
• DMAIC
• Seis Sigma
• Economics
• Leadership
• Six Sigma

Informations

• Publié par: ASQ Quality Press
• Date de parution: 10 novembre 2008
• Nombre de lectures: 0
• EAN13: 9780873891325
• Langue: English
• Poids de l'ouvrage: 2 Mo

Extrait

Process Improvement Using Six Sigma

Also available from ASQ Quality Press:

The Certified Six Sigma Black Belt Handbook,Second Edition T. M. Kubiak and Donald W. Benbow

The Certified Six Sigma Green Belt Handbook Roderick A. Munro, Matthew J. Maio, Mohamed B. Nawaz, Govindarajan Ramu, and Daniel J. Zrymiak

Six Sigma for the New Millennium: A CSSBB Guidebook,Second Edition Kim H. Pries

5S for Service Organizations and Offices: A Lean Look at Improvements Debashis Sarkar

The Executive Guide to Understanding and Implementing Lean Six Sigma: The Financial Impact Robert M. Meisel, Steven J. Babb, Steven F. Marsh, and James P. Schlichting

Applied Statistics for the Six Sigma Green Belt Bhisham C. Gupta and H. Fred Walker

Statistical Quality Control for the Six Sigma Green Belt Bhisham C. Gupta and H. Fred Walker

Six Sigma for the Office: A Pocket Guide Roderick A. Munro

Lean Six Sigma for Healthcare: A Senior Leader Guide to Improving Cost and Throughput,Second Edition Chip Caldwell, Greg Butler, and Nancy Poston.

Defining and Analyzing a Business Process: A Six Sigma Pocket Guide Jeffrey N. Lowenthal

Six Sigma for the Shop Floor: A Pocket Guide Roderick A. Munro

Six Sigma Project Management: A Pocket Guide Jeffrey N. Lowenthal

Lean Kaizen: A Simplified Approach to Process Improvements George Alukal and Anthony Manos

To request a complimentary catalog of ASQ Quality Press publications, call 8002481946, or visit our Web site at http://www.asq.org/qualitypress.

Process Improvement Using Six Sigma

A DMAIC Guide

Rama Shankar

ASQ Quality Press Milwaukee, Wisconsin

American Society for Quality, Quality Press, Milwaukee 53203 © 2009 by ASQ All rights reserved. Published 2009 Printed in the United States of America 15 14 13 12 11 10 09 5 4 3 2 1

Library of Congress CataloginginPublication Data

Shankar, Rama, 1956–  Process improvement using Six Sigma : a DMAIC guide / Rama Shankar.  p. cm.  Includes index.  ISBN 9780873897525 (soft cover : alk. paper)  1. Six sigma (Quality control standard) 2. Total quality management.  3. Process control. 4. Reengineering (Management) I. Title.  HD62.15.S477 2009  658.4'013—dc22 2008052670

ISBN: 9780873897525

No part of this book may be reproduced in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

Publisher: William A. Tony Acquisitions Editor: Matt T. Meinholz Project Editor: Paul O’Mara Production Administrator: Randall Benson

ASQ Mission: The American Society for Quality advances individual, organizational, and community excellence worldwide through learning, quality improvement, and knowledge exchange.

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To place orders or to request a free copy of the ASQ Quality Press Publications Catalog, including ASQ membership information, call 8002481946. Visit our Web site at www.asq.org or http://www.asq.org/qualitypress.

Printed in the United States of America

 Printed on acidfree paper

Om to My guru My mother My family

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Table of Contents

List of Figures and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Read Me First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acronym List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. Define. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of Define Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How Do You Identify Projects for Improvement? . . . . . . . . . . . How Do You Pick a Project? . . . . . . . . . . . . . . . . . . . . . . . . . . . How Do You Scope Your Project? The SIPOC Diagram. . . . . . Assemble the Process Improvement Team . . . . . . . . . . . . . . . . . Create a Project Authorization/Charter Document . . . . . . . . . . End of Define Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II. Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of Measure Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Develop an Understanding of Your Process—Creating Process Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Risk Management Plan FMEA. . . . . . . . . . . . . . . . . . . . . . . . . . Calculating Process Sigma for Your Process—Process Capability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating Process Sigma (Z) or Process Capability (C p and C pk ) for Variable Data . . . . . . . . . . . . . . . . . . . . . . . . Conducting Gage R&R Studies—Variable Data and Attribute Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End of Measure Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III. Analyze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of Analyze Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Are Things Improving? Running a Hypothesis Test . . . . . . . . . Can You Uncover Any Relationships? Correlation and Regression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

ix xiii xiv xv 1 1 1 2 3 6 6 9 11 11

12 14

20

23

29 38 41 41 41

48

viii

Table of Contents

ANOVA (Analysis of Variance) . . . . . . . . . . . . . . . . . . . . . . . . . End of Analyze Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV. Improve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of Improve Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Investigating Relationships between Input and Output— Running Design of Experiments (DOE) . . . . . . . . . . . . . . . . End of Improve Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V. Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of Control Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitor the Stability of the Process—Statistical Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MistakeProofing/PokaYoke . . . . . . . . . . . . . . . . . . . . . . . . . . . Technology Transfer—The Control Plan . . . . . . . . . . . . . . . . . . WrapUp—Updating Essential Documents . . . . . . . . . . . . . . . . Calculating Project Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End of Control Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 65 67 67

67 92 95 95

95 99 99 102 103 103 104

107

List of Figures and Tables

Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Table 1 Figure 13

Figure 14

Table 2 Figure 15 Figure 16

Figure 17 Figure 18 Figure 19

Table 3 Figure 20

The process model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The DMAIC process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of multiple levels of Pareto charts. . . . . . . . . . . . . . SIPOC diagram template. . . . . . . . . . . . . . . . . . . . . . . . . . . . SIPOC diagram for “going to work in the morning.” . . . . . . Example of a meeting minutes template. . . . . . . . . . . . . . . . . Example of a communication plan template. . . . . . . . . . . . . . Example of a simple charter document template. . . . . . . . . . Example of a process map for a stamping process. . . . . . . . . Example of an FMEA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summarizing raw data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Histogram for cycle time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating process sigma—variable data. . . . . . . . . . . . . . . Process capability for terminal length showing percentage overall performance. . . . . . . . . . . . . . . . . . . . . . . Process capability for terminal length showing PPM overall performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating process sigma—attribute and count data. . . . . . Gage R&R graph for inventory retains. . . . . . . . . . . . . . . . . . Minitab output for deflection measurement of electronic parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Results of deflection measurement of electronic parts. . . . . . Appraiser results for bank loan pass/fail study. . . . . . . . . . . . Attribute agreement analysis of bank loan gage R&R study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common alpha risk values. . . . . . . . . . . . . . . . . . . . . . . . . . . Results ofttest of tooling cavity dimensions. . . . . . . . . . . . .

ix

xvii xviii 4 4 5 7 8 8 15 17 21 22 24

26

27 27 31

33 34 36

37 42 44