Cover image for Implementing six sigma and lean : a practical guide to tools and techniques
Title:
Implementing six sigma and lean : a practical guide to tools and techniques
Personal Author:
Publication Information:
Oxford, UK : Elsevier, 2009
Physical Description:
xix, 342 p. : ill. ; 24 cm.
ISBN:
9781856175203

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30000010214558 TS156 B433 2009 Open Access Book
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Summary

Summary

This is a comprehensive, user-friendly and hands-on book that is a single source of reference of tools and techniques for all quality practitioners. Implementing Six Sigma and Lean covers the basics of how to manage for consistently high quality and gives good coverage of both simple tools and advanced techniques which can be used in all businesses. This book provides guidance on how to use these tools for different situations such as new start-up companies, stalled projects and the constant achievement of high quality in well-established quality regimes. Case studies are included that encourage the reader to respond in a practical situations and provide a good learning resource for courses. There are summaries of key elements and questions with exercises at the end of each chapter.


Table of Contents

Prefacep. xiii
Acknowledgementp. xxi
About the authorp. xxiii
Part 1 The Foundations of Qualityp. 1
1 Quality and operational excellencep. 3
Introductionp. 3
Tools and techniquesp. 3
What is qualityp. 4
Hierarchy of qualityp. 8
Cost of qualityp. 10
Waves of quality managementp. 11
Operational Excellencep. 16
2 History of the quality movementp. 18
Introductionp. 18
World classp. 19
W. Edwards Demingp. 19
Joseph M. Juranp. 21
Armand V. Feigenbaump. 22
Philip B. Crosbyp. 22
Hammer and Champyp. 23
What of the Japanese?p. 24
Lean Enterprisep. 25
Total Productive Maintenancep. 26
Basu and Wright and TQMp. 27
American and European approaches to TQMp. 29
Jan Carlzonp. 30
ISO 9000p. 30
Kaizenp. 33
Quality Circlesp. 34
Quality Project Teamsp. 35
Ishikawa (Fishbone technique) or Cause and Effectp. 35
Compatibility with FIT SIGMAp. 36
New trendsp. 36
3 The scope of tools and techniquesp. 38
Introductionp. 38
The drivers for tools and techniquesp. 38
The problems of using tools and techniquesp. 39
The critical success factorsp. 44
Summary of Part 1p. 47
Part 1: Questions and exercisesp. 48
Part 2 Toolsp. 51
4 Tools for definitionp. 53
D1 IPO Diagramp. 53
D2 SIPOC Diagramp. 55
D3 Flow Diagramp. 56
D4 CTQ Treep. 59
D5 Project Charterp. 60
Summaryp. 63
5 Tools for measurementp. 64
Introductionp. 64
M1 Check Sheetsp. 65
M2 Histogramsp. 67
M3 Run Chartsp. 70
M4 Scatter Diagramsp. 71
M5 Cause and Effect Diagramsp. 73
M6 Pareto Chartsp. 76
M7 Control Chartsp. 79
M8 Flow Process Chartsp. 82
M9 Process Capability Measurementp. 85
6 Tools for analysisp. 89
Introductionp. 89
A1 Process Mappingp. 90
A2 Regression Analysisp. 92
A3 RU/CS Analysisp. 94
A4 SWOT Analysisp. 97
A5 PESTLE Analysisp. 99
A6 The Five Whysp. 101
A7 Interrelationship Diagramp. 102
A8 Overall Equipment Effectivenessp. 104
A9 TRIZ: Innovative Problem Solvingp. 108
7 Tools for improvementp. 112
I1 Affinity Diagramp. 113
I2 Nominal Group Techniquep. 115
I3 SMEDp. 116
I4 Five Sp. 118
I5 Mistake Proofingp. 121
I6 Value Stream Mappingp. 122
I7 Brainstormingp. 125
I8 Mind Mappingp. 127
I9 Force Field Analysis Diagramp. 130
8 Tools for controlp. 133
Introductionp. 133
C1 Gantt Chartp. 134
C2 Activity Network Diagramp. 136
C3 Radar Chartp. 138
C4 PDCA Cyclep. 140
C5 Milestone Tracker Diagramp. 142
C6 Earned Value Managementp. 144
Summary of Part 2p. 149
Part 2: Questions and exercisesp. 150
Part 3 Techniquesp. 153
9 Quantitative techniquesp. 155
Introductionp. 155
Selection of techniquesp. 155
Structure of presentationp. 156
Q1 Failure Mode and Effects Analysisp. 156
Q2 Statistical Process Controlp. 159
Q3 Quality Function Deploymentp. 166
Q4 Design of Experimentsp. 171
Q5 Define, Measure, Analyse, Improve, Controlp. 177
Q6 Design for Six Sigmap. 183
Q7 Monte Carlo techniquep. 188
10 Qualitative techniquesp. 195
Introductionp. 195
R1 Benchmarkingp. 195
R2 The Balanced Scorecardp. 199
R3 European Foundation of Quality Managementp. 206
R4 Sales and Operations Planningp. 212
R5 Kanbanp. 218
R6 Activity Based Costingp. 222
R7 Quality Management Systemsp. 226
R8 Lean Thinkingp. 231
Summary of Part 3p. 238
Part 3: Questions and exercisesp. 239
Part 4 Implementationp. 241
11 Making it happenp. 243
Introductionp. 243
Selection of tools and techniquesp. 243
Implementation for new startersp. 246
12 Case studiesp. 267
Introductionp. 267
Product innovation at Elida Faberge, UKp. 267
Lean Manufacturing at aluminium industry, USAp. 269
Supply chain logistics at National Starch, USAp. 271
Six Sigma in General Electric, USAp. 272
Integrating Lean and supply chain in Seagate, USAp. 277
FIT SIGMA at a SME, Swedenp. 279
Performance monitoring at Dupont Teijin Films, UKp. 280
Total productive maintenance at Nippon Lever, Japanp. 281
Sales and operations planning at GSK, Turkeyp. 283
Six Sigma training at Noranda, Canadap. 285
Self-assessment at Jansen-Cilag, UKp. 286
Total quality at Chesebrough-Pond's, Jefferson Cityp. 287
Sustaining Six Sigma by Leadership Forums in Pliva Croatiap. 288
Lean Sigma changes a pharma culturep. 290
Summary of Part 4p. 292
Part 4: Questions and exercisesp. 293
Appendix 1 Management modelsp. 295
Introductionp. 295
A1 Ansoff's product/market matrixp. 295
A2 Basu's outsourcing matrixp. 297
A3 The BCG matrixp. 298
A4 Belbin's team rolesp. 300
A5 Economic value addedp. 302
A6 The Fifth Disciplinep. 303
A7 The McKinsey 7-S frameworkp. 305
A8 Kano's satisfaction modelp. 307
A9 Mintzberg's organisational configurationp. 308
A10 Porter's competitive advantagep. 311
A11 Porter's five forcesp. 312
A12 Porter's Value Chainp. 314
A13 Turner's Project Goals and Methods Matrixp. 316
A14 Wild's taxonomy of systems structuresp. 317
Appendix 2 Introduction to basic statisticsp. 320
Statisticsp. 320
Descriptive statisticsp. 320
Normal Distributionp. 320
Measures of central tendencyp. 321
Measure of dispersionp. 322
Skewness and Kurtosisp. 322
Sources of variationp. 322
Process capabilityp. 323
Process Sigmap. 323
Inferential statisticsp. 323
Causal modellingp. 325
SPSSp. 325
Appendix 3 Random nominal numbersp. 326
Appendix 4 Answer to numeric exercisesp. 327
Part 2p. 327
Part 3p. 328
Referencesp. 329
Glossaryp. 336
Indexp. 343