Implementing six sigma and lean : a practical guide to tools and techniques

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Title:

Personal Author:

Basu, Ron

Publication Information:

Oxford, UK : Elsevier, 2009

Physical Description:

xix, 342 p. : ill. ; 24 cm.

ISBN:

9781856175203

Subject Term:

Quality control -- Statistical methods

Production management -- Statistical methods

Available:*

Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010214558	TS156 B433 2009	Open Access Book	Book	Searching... Unknown
Searching... PSZ KL	30000010203647	TS156 B433 2009	Open Access Book	Book	Searching... Unknown

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.

Author Notes

Ron Basu

Preface	p. xiii
Acknowledgement	p. xxi
About the author	p. xxiii
Part 1 The Foundations of Quality	p. 1
1 Quality and operational excellence	p. 3
Introduction	p. 3
Tools and techniques	p. 3
What is quality	p. 4
Hierarchy of quality	p. 8
Cost of quality	p. 10
Waves of quality management	p. 11
Operational Excellence	p. 16
2 History of the quality movement	p. 18
Introduction	p. 18
World class	p. 19
W. Edwards Deming	p. 19
Joseph M. Juran	p. 21
Armand V. Feigenbaum	p. 22
Philip B. Crosby	p. 22
Hammer and Champy	p. 23
What of the Japanese?	p. 24
Lean Enterprise	p. 25
Total Productive Maintenance	p. 26
Basu and Wright and TQM	p. 27
American and European approaches to TQM	p. 29
Jan Carlzon	p. 30
ISO 9000	p. 30
Kaizen	p. 33
Quality Circles	p. 34
Quality Project Teams	p. 35
Ishikawa (Fishbone technique) or Cause and Effect	p. 35
Compatibility with FIT SIGMA	p. 36
New trends	p. 36
3 The scope of tools and techniques	p. 38
Introduction	p. 38
The drivers for tools and techniques	p. 38
The problems of using tools and techniques	p. 39
The critical success factors	p. 44
Summary of Part 1	p. 47
Part 1: Questions and exercises	p. 48
Part 2 Tools	p. 51
4 Tools for definition	p. 53
D1 IPO Diagram	p. 53
D2 SIPOC Diagram	p. 55
D3 Flow Diagram	p. 56
D4 CTQ Tree	p. 59
D5 Project Charter	p. 60
Summary	p. 63
5 Tools for measurement	p. 64
Introduction	p. 64
M1 Check Sheets	p. 65
M2 Histograms	p. 67
M3 Run Charts	p. 70
M4 Scatter Diagrams	p. 71
M5 Cause and Effect Diagrams	p. 73
M6 Pareto Charts	p. 76
M7 Control Charts	p. 79
M8 Flow Process Charts	p. 82
M9 Process Capability Measurement	p. 85
6 Tools for analysis	p. 89
Introduction	p. 89
A1 Process Mapping	p. 90
A2 Regression Analysis	p. 92
A3 RU/CS Analysis	p. 94
A4 SWOT Analysis	p. 97
A5 PESTLE Analysis	p. 99
A6 The Five Whys	p. 101
A7 Interrelationship Diagram	p. 102
A8 Overall Equipment Effectiveness	p. 104
A9 TRIZ: Innovative Problem Solving	p. 108
7 Tools for improvement	p. 112
I1 Affinity Diagram	p. 113
I2 Nominal Group Technique	p. 115
I3 SMED	p. 116
I4 Five S	p. 118
I5 Mistake Proofing	p. 121
I6 Value Stream Mapping	p. 122
I7 Brainstorming	p. 125
I8 Mind Mapping	p. 127
I9 Force Field Analysis Diagram	p. 130
8 Tools for control	p. 133
Introduction	p. 133
C1 Gantt Chart	p. 134
C2 Activity Network Diagram	p. 136
C3 Radar Chart	p. 138
C4 PDCA Cycle	p. 140
C5 Milestone Tracker Diagram	p. 142
C6 Earned Value Management	p. 144
Summary of Part 2	p. 149
Part 2: Questions and exercises	p. 150
Part 3 Techniques	p. 153
9 Quantitative techniques	p. 155
Introduction	p. 155
Selection of techniques	p. 155
Structure of presentation	p. 156
Q1 Failure Mode and Effects Analysis	p. 156
Q2 Statistical Process Control	p. 159
Q3 Quality Function Deployment	p. 166
Q4 Design of Experiments	p. 171
Q5 Define, Measure, Analyse, Improve, Control	p. 177
Q6 Design for Six Sigma	p. 183
Q7 Monte Carlo technique	p. 188
10 Qualitative techniques	p. 195
Introduction	p. 195
R1 Benchmarking	p. 195
R2 The Balanced Scorecard	p. 199
R3 European Foundation of Quality Management	p. 206
R4 Sales and Operations Planning	p. 212
R5 Kanban	p. 218
R6 Activity Based Costing	p. 222
R7 Quality Management Systems	p. 226
R8 Lean Thinking	p. 231
Summary of Part 3	p. 238
Part 3: Questions and exercises	p. 239
Part 4 Implementation	p. 241
11 Making it happen	p. 243
Introduction	p. 243
Selection of tools and techniques	p. 243
Implementation for new starters	p. 246
12 Case studies	p. 267
Introduction	p. 267
Product innovation at Elida Faberge, UK	p. 267
Lean Manufacturing at aluminium industry, USA	p. 269
Supply chain logistics at National Starch, USA	p. 271
Six Sigma in General Electric, USA	p. 272
Integrating Lean and supply chain in Seagate, USA	p. 277
FIT SIGMA at a SME, Sweden	p. 279
Performance monitoring at Dupont Teijin Films, UK	p. 280
Total productive maintenance at Nippon Lever, Japan	p. 281
Sales and operations planning at GSK, Turkey	p. 283
Six Sigma training at Noranda, Canada	p. 285
Self-assessment at Jansen-Cilag, UK	p. 286
Total quality at Chesebrough-Pond's, Jefferson City	p. 287
Sustaining Six Sigma by Leadership Forums in Pliva Croatia	p. 288
Lean Sigma changes a pharma culture	p. 290
Summary of Part 4	p. 292
Part 4: Questions and exercises	p. 293
Appendix 1 Management models	p. 295
Introduction	p. 295
A1 Ansoff's product/market matrix	p. 295
A2 Basu's outsourcing matrix	p. 297
A3 The BCG matrix	p. 298
A4 Belbin's team roles	p. 300
A5 Economic value added	p. 302
A6 The Fifth Discipline	p. 303
A7 The McKinsey 7-S framework	p. 305
A8 Kano's satisfaction model	p. 307
A9 Mintzberg's organisational configuration	p. 308
A10 Porter's competitive advantage	p. 311
A11 Porter's five forces	p. 312
A12 Porter's Value Chain	p. 314
A13 Turner's Project Goals and Methods Matrix	p. 316
A14 Wild's taxonomy of systems structures	p. 317
Appendix 2 Introduction to basic statistics	p. 320
Statistics	p. 320
Descriptive statistics	p. 320
Normal Distribution	p. 320
Measures of central tendency	p. 321
Measure of dispersion	p. 322
Skewness and Kurtosis	p. 322
Sources of variation	p. 322
Process capability	p. 323
Process Sigma	p. 323
Inferential statistics	p. 323
Causal modelling	p. 325
SPSS	p. 325
Appendix 3 Random nominal numbers	p. 326
Appendix 4 Answer to numeric exercises	p. 327
Part 2	p. 327
Part 3	p. 328
References	p. 329
Glossary	p. 336
Index	p. 343

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Summary

Summary

Author Notes

Table of Contents