This significantly revised second edition of Implementing Six Sigma goes well beyond traditional methodologies, introducing an enhanced roadmap which offers a solution to the common problem of sustaining six sigma activities, while downplaying the traditional policy that six sigma projects must have a defined defect. A variety of plans, checklists, metrics, and warnings of potential pitfalls provide thorough preparation for anyone implementing six sigma strategies.

From the Preface: “This book provides a roadmap for the creation of an enterprise system in which organizations can significantly improve both customer satisfaction and their bottom line. The described techniques help manufacturing, development, and service organizations become more competitive and/or move them to new heights. This book describes a structured approach for the tracking and attainment of organizational goals through the wise implementation of traditional Six Sigma techniques and other methodologies — throughout the whole enterprise of an organization...”

Target Audience: Quality engineers, managers, technicians, and gauging and inspection specialists; process control engineers and managers; and any other practitioner or student concerned with six sigma or continuous improvement programs.

Table of Contents:

S⁴ Deployment and Define Phase from DMAIC:

Six Sigma Overview and S⁴/IEE Implementation

Voice of the Customer and the S⁴/IEE Define Phase

S⁴/IEE Measure Phase from DMAIC:

Measurements and the S⁴/IEE Measure Phase

Process Flowcharting/Process Mapping

Basic Tools

Probability

Overview of Distributions and Statistical Processes

Probability and Hazard Plotting

Six Sigma Measurements

Basic Control Charts

Process Capability and Process Performance Metrics

Measurement Systems Analysis

Cause-and-Effect Matrix and Quality Function Deployment

FMEA

S⁴/IEE Analyze Phase from DMAIC (or Passive Analysis Phase):

Visualization of Data

Confidence Intervals and Hypothesis Tests

Inferences: Continuous Response

Inferences: Attribute (Pass/Fail) Response

Comparison Tests: Continuous Response

Comparison Tests: Attribute (Pass/Fail) Response

Bootstrapping

Variance Components

Correlation and Simple Linear Regression

Single-Factor (One-Way) Analysis of Variance (ANOVA) and Analysis of Means (ANOM)

Two-Factor (Two-Way) Analysis of Variance

Multiple Regression, Logistic Regression, and Indicator Variables

S⁴/IEE Improve Phase from DMAIC (or Proactive Testing Phase):

Benefitting from Design of Experiments (DOE)

Understanding the Creation of Full and Fractional Factorial 2^k DOEs

Planning 2^k DOEs

Design and Analysis of 2^k DOEs

Other DOE Considerations

Robust DOE

Response Surface Methodology

S⁴/IEE Control Phase from DMAIC and Applications Examples:

Short-Run and Target Control Charts

Control Charting Alternatives

Exponentially Weighted Moving Average (EWMA) and Engineering Process Control (EPC)

Pre-Control Charts

Control Plan, Poka-yoke, Realistic Tolerancing, and Project Completion

Reliability Testing/Assessment: Overview

Reliability Testing/Assessment: Repairable System

Reliability Testing/Assessment: Nonrepairable Devices

Pass/Fail Functional Testing

S⁴/IEE Application Examples

S⁴/IEE and Theory of Constraints:

Lean and Its Integration with S⁴/IEE

Integration of Theory of Constraints (TOC) in S⁴/IEE

DFSS and 21-Step Integration of the Tools:

Manufacturing Applications and a 21-Step Integration of the Tools

Service/Transactional Applications and a 21-Step Integration of the Tools

DFSS Overview and Tools

Product DFSS

Process DFSS

Management of Infrastructure and Team Execution:

Change Management

Project Management and Financial Analysis

Team Effectiveness

Creativity

Alignment of Management Initiatives and Strategies with S⁴/IEE

Appendices and Tables

Glossary

References

Index