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Cover image for The Six Sigma handbook : a complete guide for green belts, black belts, and managers at all levels
The Six Sigma handbook : a complete guide for green belts, black belts, and managers at all levels
Personal Author:
Rev. and expanded ed.
Publication Information:
New York, NY : McGraw-Hill, 2003


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Item Category 1
30000004717801 TS155 P99 2003 Open Access Book Book

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Contains a 700-page guide to the quality tools and statistics that are the foundation for Six Sigma. This book provides an overview of the management goals, training issues involved in a Six Sigma implementation, and the underlying philosophy. It explains the problem-solving techniques and statistical tools most often used in Six Sigma.

Author Notes

Thomas Pyzdek, Thomas Pyzdek earned his Bachelor's Degree in Liberal Arts from the University of Nebraska at Omaha and earned his Master's in Systems Engineering in 1982, and Management in 1995, from the University of Arizona.

Pyzdek taught management statistics at the University of Arizona and for the American Society for Quality. He is a fellow of ASQ and is certified as both a Quality Engineer and a Reliability Engineer. Pyzdek has consulted for such large companies as Avon, McDonalds and Federal Mogul. He himself has launched two successful companies, Quality America, Inc, that specializes in statistical software, and Quality Publishing, Inc. which specializes in books and multimedia training materials. He also writes a regular column for Quality Digest Magazine.

In 1995, Pyzdek was awarded the ASQ Edwards Medal for outstanding contributions to the practice of quality management. He also received the Hughes Engineering Master's Fellowship in 1980. He was a member of the Board of Examiners for the first Malcolm Baldridge National Quality Award and the Panel of Judges for the first Arizona Govenor's Award for Quality. Pyzdek is listed as an Outstanding Writer and Author by the INternational Who's Who in Quality.

Table of Contents

Prefacep. xiii
Introductionp. xvi
Part I Six Sigma Implementation and Managementp. 1
Chapter 1 Building the Six Sigma Infrastructurep. 3
What is Six Sigma?p. 3
Implementing Six Sigmap. 20
Change agent compensation and retentionp. 54
Chapter 2 Six Sigma Goals and Metricsp. 56
Attributes of good metricsp. 56
Six Sigma versus traditional three sigma performancep. 58
The balanced scorecardp. 61
Strategy deployment planp. 71
Information systems requirementsp. 74
Dashboard designp. 79
Setting organizational key requirementsp. 89
Chapter 3 Creating Customer-Driven Organizationsp. 97
Elements of customer-driven organizationsp. 97
Surveys and focus groupsp. 102
Calculating the value of retention of customersp. 116
Kano model of customer expectationsp. 119
Quality function deployment (QFD)p. 121
The Six Sigma process enterprisep. 125
Using QFD to link Six Sigma projects to strategiesp. 132
Linking customer demands to budgetsp. 140
Chapter 4 Training for Six Sigmap. 150
Training needs analysisp. 150
The strategic training planp. 152
Chapter 5 Six Sigma Teamsp. 167
Six Sigma teamsp. 167
Process improvement teamsp. 168
Work groupsp. 169
Other self-managed teamsp. 170
Team dynamics management, including conflict resolutionp. 171
Facilitation techniquesp. 178
Team performance evaluationp. 182
Team recognition and rewardp. 184
Chapter 6 Selecting and Tracking Six Sigma Projectsp. 187
Choosing the right projectsp. 188
Analyzing project candidatesp. 189
Tracking Six Sigma project resultsp. 208
Part II Six Sigma Tools and Techniquesp. 235
Chapter 7 Introduction to DMAIC and Other Improvement Modelsp. 237
DMAIC, DMADV and learning modelsp. 237
The Define Phase
Chapter 8 Problem Solving Toolsp. 252
Process mappingp. 252
Check sheetsp. 255
Pareto analysisp. 259
Cause and effect diagramsp. 261
7M toolsp. 264
The Measure Phase
Chapter 9 Basic Principles of Measurementp. 277
Scales of measurementp. 277
Reliability and validity of datap. 280
Overview of statistical methodsp. 283
Principles of statistical process controlp. 318
Chapter 10 Measurement Systems Analysisp. 325
R&R studies for continuous datap. 325
Attribute measurement error analysisp. 346
Repeatability and pairwise reproducibilityp. 352
The Analyze Phase
Chapter 11 Knowledge Discoveryp. 361
Knowledge discovery toolsp. 361
Establishing the process baselinep. 385
SIPOCp. 383
Chapter 12 Statistical Process Control Techniquesp. 393
Statistical process control (SPC)p. 393
EWMAp. 453
Chapter 13 Process Capability Analysisp. 467
Process capability analysis (PCA)p. 467
Estimating process yieldp. 484
Chapter 14 Statistical Analysis of Cause and Effectp. 490
Testing common assumptionsp. 490
Regression and correlation analysisp. 496
Analysis of categorical datap. 514
Non-parametric methodsp. 528
The Improve Phase
Chapter 15 Managing Six Sigma Projectsp. 534
Useful project management tools and techniquesp. 535
Project charterp. 538
Work breakdown structuresp. 541
Feedback loopsp. 543
Performance measuresp. 544
Cost considerations in project schedulingp. 552
Project management implementationp. 560
Chapter 16 Risk Assessmentp. 571
Reliability and safety analysisp. 571
Failure mode and effect analysis (FMEA)p. 596
Statistical tolerancingp. 600
Chapter 17 Design of Experiments (DOE)p. 607
Terminologyp. 608
Power and sample sizep. 610
Design characteristicsp. 610
Types of designp. 611
Examples of applying common DOE methods using softwarep. 616
Empirical model building and sequential learningp. 624
Data mining, artificial neural networks and virtual process mappingp. 644
The Control Phase
Chapter 18 Maintaining Control After the Projectp. 649
Business process control planningp. 649
Using SPC for ongoing controlp. 652
Process control planning for short and small runsp. 655
Preparing the short run process control plain (PCP)p. 656
PRE-Controlp. 661
Beyond DMAIC
Chapter 19 Design for Six Sigma (DFSS)p. 665
Preliminary stepsp. 665
Definep. 667
Measurep. 670
Analyzep. 671
Designp. 682
Verifyp. 703
Chapter 20 Lean Manufacturing and Six Sigmap. 705
Introduction to Lean and mudap. 705
What is value to the customer?p. 706
What is the value stream?p. 708
How do we make value flow?p. 711
How do we make value flow at the pull of the customer?p. 713
How can we continue towards perfection?p. 716
Becoming Lean: A tactical perspectivep. 720
Six Sigma and Leanp. 721
Appendixp. 724
Table 1 Glossary of basic statistical termsp. 724
Table 2 Area under the standard normal curvep. 730
Table 3 Critical values of the t-distributionp. 733
Table 4 Chi-square distributionp. 735
Table 5 F distribution ([alpha] = 1%)p. 738
Table 6 F distribution ([alpha] = 5%)p. 740
Table 7 Poisson probability sumsp. 742
Table 8 Tolerance interval factorsp. 746
Table 9 Durbin-Watson test boundsp. 750
Table 10 y factors for computing AOQLp. 754
Table 11 Control chart constantsp. 755
Table 12 Control chart equationsp. 757
Table 13 Table of d*[subscript 2] valuesp. 759
Table 14 Power functions for ANOVAp. 761
Table 15 Factors for short run control charts for individuals, X-bar, and R chartsp. 770
Table 16 Significant number of consecutive highest or lowest values from one stream of a multiple-stream processp. 772
Table 17 Sample customer surveyp. 773
Table 18 Process [sigma] levels and equivalent PPM quality levelsp. 777
Table 19 Black Belt effectiveness certificationp. 778
Table 20 Green Belt effectiveness certificationp. 791
Table 21 AHP using Microsoft Excelp. 804
Referencesp. 806
Indexp. 814
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