Simulation-based design for lean six sigma : transactional process engineering

This is the first book to completely cover the whole body of knowledge of Six Sigma and Design for Six Sigma with Simulation Methods as outlined by the American Society for Quality. Both simulation and contemporary Six Sigma methods are explained in detail with practical examples that help understanding of the key features of the design methods. The systems approach to designing products and services as well as problem solving is integrated into the methods discussed.

Author Notes

Basem El-Haik, PhD, is a Six Sigma and Design for Six Sigma consultant, author, and founder of Six Sigma Professionals, Inc.
Raid Al-Aomar, PhD, is Assistant Professor of Industrial Engineering at Jordan University of Science and Technology (JUST)

Preface	p. xi
Part I Six-Sigma Fundamentals	p. 1
1 Six-Sigma Fundamentals	p. 3
1.1 Introduction	p. 3
1.2 Quality and Six-Sigma Defined	p. 5
1.3 Introduction to Process Modeling	p. 7
1.4 Introduction to Business Process Management	p. 9
1.5 Measurement Systems Analysis	p. 11
1.6 Process Capability and Six-Sigma Process Performance	p. 12
1.7 Overview of Six-Sigma Improvement: DMAIC	p. 15
1.8 Six-Sigma Goes Upstream: Design for Six-Sigma	p. 18
1.9 Summary	p. 18
2 Lean Six-Sigma Fundamentals	p. 21
2.1 Introduction	p. 21
2.2 Lean Six-Sigma Approach	p. 23
2.3 LSS-Enhanced DMAIC	p. 26
2.4 Lean Manufacturing	p. 30
2.5 Value Stream Mapping	p. 35
2.6 Lean Techniques	p. 39
2.7 Summary	p. 57
3 Design for Six-Sigma Fundamentals	p. 59
3.1 Introduction	p. 59
3.2 Transaction-Based Design for Six-Sigma	p. 61
3.3 Service Design for Six-Sigma	p. 63
3.4 Service DFSS: The ICOV Process	p. 65
3.5 Service DFSS: The ICOV Process in Service Development	p. 68
3.6 Summary	p. 69
Part II Simulation Fundamentals	p. 71
4 Basic Simulation Concepts	p. 73
4.1 Introduction	p. 73
4.2 System Modeling	p. 74
4.3 Simulation Modeling	p. 84
4.4 The Role of Simulation	p. 89
4.5 Simulation Software	p. 95
4.6 Summary	p. 96
5 Discrete Event Simulation	p. 99
5.1 Introduction	p. 99
5.2 System Modeling with DES	p. 100
5.3 Elements of Discrete Event Simulation	p. 104
5.4 DES Mechanisms	p. 112
5.5 Manual Simulation Example	p. 121
5.6 Computer DES Example	p. 126
5.7 Summary	p. 131
6 The Simulation Process	p. 133
6.1 Introduction	p. 133
6.2 Categories of Simulation Studies	p. 134
6.3 Systematic Simulation Approach	p. 139
6.4 Steps in a Simulation Study	p. 144
6.5 Example: Applying Simulation Process to a Hospital Emergency Room	p. 158
6.6 Summary	p. 166
7 Simulation Analysis	p. 167
7.1 Introduction	p. 167
7.2 Terminating Versus Steady-State Simulation	p. 168
7.3 Determination of Simulation Run Controls	p. 172
7.4 Variability in Simulation Outputs	p. 181
7.5 Simulation-Based Optimization	p. 185
Part III Simulation-Based Six-Sigma and Design for Six-Sigma	p. 189
8 Simulation-Based Six-Sigma Road Maps	p. 191
8.1 Introduction	p. 191
8.2 Lean Six-Sigma Process Overview	p. 192
8.3 Simulation-Based Lean Six-Sigma Road Map	p. 194
8.4 Simulation-Based Design for a Six-Sigma Road Map	p. 203
8.5 Summary	p. 218
9 Simulation-Based Lean Six-Sigma Application	p. 219
9.1 Introduction	p. 219
9.2 3S-LSS Integrated Approach	p. 221
9.3 3S-LSS Case Study	p. 226
9.4 Summary	p. 265
10 Simulation-Based Design for Six-Sigma Application	p. 267
10.1 Introduction	p. 267
10.2 3S-DFSS Process	p. 269
10.3 3S-DFSS Case Study: Dental Clinic Redesign	p. 270
10.4 Summary	p. 306
11 Practical Guide to Successful Development of Simulation-Based Six-Sigma Projects	p. 307
11.1 Introduction	p. 307
11.2 Characteristics of a 3S Application	p. 308
11.3 Ingredients for a Successful 3S Program	p. 315
11.4 Framework for Successful 3S Implementation	p. 317
11.5 3S Project Charter	p. 324
11.6 3S Software Tools	p. 326
Appendix A Basic Statistics	p. 343
Appendix B Random Numbers	p. 363
Appendix C Axiomatic Design	p. 367
Appendix D Taguchi's Quality Engineering	p. 375
Appendix E Process Mapping	p. 381
Appendix F Vendors	p. 387
References and Further Reading	p. 395
Index	p. 401

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Author Notes

Table of Contents