Preface | p. ix |
In Keeping | p. xiii |
Acknowledgments | p. xv |
About the Author | p. xvii |
Web Added Value | p. xix |
The Quest for Productivity | p. 1 |
What Is Productivity? | p. 2 |
Productivity and Global Implications: Outsourcing | p. 4 |
Quality and Productivity: A Historical Perspective | p. 4 |
The Cost of Poor Quality | p. 6 |
Quality Improvement and Corporate America | p. 7 |
The Value Proposition of Quality Improvement | p. 8 |
The Beneifts of the Quality Movement in Corporate America | p. 9 |
The Quality Movement in America Has Delivered on Its Promise | p. 10 |
Malcolm Baldrige National Quality Program | p. 10 |
Six Sigma Quality Improvement | p. 11 |
The Foundation of the Quality Movement in America | p. 12 |
Conclusion | p. 13 |
It's the Process! | p. 15 |
Paying the Ultimate Price for Not Being Process Perfect | p. 15 |
It's the Process! | p. 16 |
Process Vocabulary: A Common Language | p. 17 |
Properties of a Well-Designed Process Management System | p. 17 |
Process Design | p. 21 |
Flowcharting: A Traditional Process Mapping Method | p. 21 |
SIPOC Process Mapping | p. 24 |
Requirements Based Process Design | p. 27 |
Creating Cross-Functional Organizations | p. 31 |
Conclusion | p. 33 |
The Voice of the Customer | p. 35 |
What Is the Voice of the Customer? | p. 36 |
Why Focus on Customer Loyalty? | p. 36 |
Properties of a Well-Designed Customer Loyalty Model | p. 38 |
How to Assess the Voice of the Customer | p. 40 |
Voice of the Customer Assessment Techniques | p. 41 |
Qualitative Research Methods | p. 42 |
Quantitative Research: Surveys | p. 43 |
Assessing the Voice of the Customer: An Analysis of Customer Importance and Satisfaction | p. 47 |
Conclusion | p. 50 |
Analyzing Performance Variation | p. 51 |
Analyzing Performance Variation | p. 51 |
The Scientific Basis for Performance Variation | p. 52 |
What Is Performance Variation? | p. 53 |
Analyzing Baseline Performance: The Run Chart | p. 54 |
Common Cause and Special Cause Management Actions | p. 62 |
Conclusion | p. 62 |
The Basic Six Sigma Tool Kit | p. 63 |
The Six Sigma Analytical Tool Kit | p. 63 |
Data Sheet | p. 65 |
Histogram | p. 66 |
Cause and Effect Diagram | p. 71 |
Scatter Diagram | p. 75 |
Pareto Analysis | p. 79 |
Statistical Process Control for Service Excellence | p. 84 |
Control Chart Selection | p. 85 |
Control Chart Descriptions | p. 90 |
XmR Chart: Individual Measurement with Moving Range Chart | p. 90 |
X,R Chart: Average and Range Chart | p. 94 |
X,S Chart: Average and Standard Deviation Chart | p. 99 |
p Chart: Proportion of Defectives Chart | p. 104 |
np Chart: Number of Defectives Chart | p. 107 |
c Chart: Number of Defects Chart | p. 110 |
u Chart: Average Number of Defects per Unit Chart | p. 113 |
Performance Variation: A Review | p. 116 |
Control Chart Analysis | p. 117 |
Performance Evaluation: Process Capability Analysis | p. 123 |
Conclusion | p. 128 |
Performance Metrics and Dashboards: Building Your Performance Measurement System | p. 131 |
The Value Stream | p. 132 |
The Hidden Factory | p. 133 |
Measuring Service Quality | p. 135 |
Measuring Service Efficiency | p. 137 |
Measuring Service Production | p. 138 |
Measuring Operational Effectiveness | p. 139 |
Measuring Cost Effectiveness | p. 141 |
Conclusion | p. 143 |
The Six Sigma Project Team | p. 145 |
Team Roles and Responsibilities | p. 145 |
Project Team Leader: Black Belt/Green Belt | p. 145 |
Project Team Facilitator: Master Black Belt/Black Belt | p. 147 |
Project Team Member: Green Belt or Yellow Belt | p. 148 |
How to Establish a Six Sigma Project Team | p. 149 |
How to Support Six Sigma Project Teams | p. 149 |
Stages of Team Evolution | p. 150 |
Forming | p. 150 |
Storming | p. 151 |
Norming | p. 151 |
Performing | p. 152 |
Remedies for the Problems of Team Evolution | p. 152 |
Conclusion | p. 153 |
Six Sigma Soft Skills: Working with and through Others | p. 155 |
Successful Team Attributes | p. 156 |
Acceptable Norms: Ground Rules | p. 156 |
Purpose | p. 158 |
Developing a Mission Statement | p. 158 |
Consensus Building | p. 161 |
Groupthink | p. 163 |
Understanding and Managing Change | p. 165 |
Change and the Six Sigma Experience | p. 166 |
Unfreezing the Business Context | p. 167 |
Implement Six Sigma | p. 168 |
Refreeze the Business Context | p. 169 |
Conclusion | p. 169 |
Management by Fact: The DMAIC Approach to Performance Improvement | p. 171 |
Fire Fighting | p. 171 |
What Is Management by Fact? | p. 172 |
What Is Six Sigma? | p. 173 |
What Six Sigma Is Not | p. 174 |
Key Six Sigma Concepts | p. 174 |
From Root Cause to Performance Improvement: PDCA | p. 176 |
The DMAIC Process: A Structured Approach to Improvement | p. 177 |
Define Phase | p. 178 |
Measure Phase | p. 181 |
Analyze Phase | p. 184 |
Improve Phase | p. 186 |
Control Phase | p. 187 |
Six Sigma Project Management Overview | p. 187 |
Six Sigma Master Project Plan | p. 188 |
Six Sigma Personal Action Plan | p. 188 |
Business Reviews and Project Briefings | p. 189 |
Conclusion | p. 193 |
Deploying Your Performance Excellence System | p. 195 |
Attributes of a Strong Performance Excellence System | p. 196 |
Focusing on Core Operating Processes | p. 198 |
Integrating Measurements | p. 199 |
Eliminating Non-Value-Added Tasks | p. 201 |
Conclusion | p. 203 |
The Fundamentals of Lean Thinking for Service Excellence: Doing More with Less! | p. 205 |
Lean Thinking | p. 205 |
What Is Lean? | p. 205 |
Value: Value Creation and Value Added | p. 207 |
Muda: Waste, Waste, Waste | p. 210 |
Value Stream Mapping: Eliminating the Six Sources of Service Muda | p. 212 |
Determine the Service Process | p. 213 |
Map the Current State | p. 213 |
Analyze the Process | p. 214 |
Define the Future State | p. 214 |
PDCA: Plan, Do, Check, Act | p. 215 |
5S: Getting Your Service House in Order | p. 215 |
Sort | p. 216 |
Set in Order | p. 217 |
Shine | p. 217 |
Standardize | p. 217 |
Sustain | p. 218 |
Conclusion | p. 218 |
Lean Six Sigma Service Excellence: A Road Map to Green Belt Certification | p. 219 |
Lean Six Sigma Service Excellence Green Belt Certification Program | p. 220 |
Tools | p. 221 |
Glossary | p. 223 |
References | p. 233 |
Chapter 4 Exercise Answers | p. 235 |
Run Chart Construction Exercise | p. 235 |
Run Chart Analysis Exercises | p. 236 |
Chapter 5 Exercise Answers | p. 239 |
Histogram Exercise | p. 239 |
Cause and Effect Diagram Exercise | p. 240 |
Scatter Diagram Exercise | p. 241 |
Pareto Analysis Exercise | p. 242 |
Control Chart Selection Exercises | p. 246 |
Control Chart Analysis Exercise | p. 247 |
Additional Lean Six Sigma Tools and Methods | p. 249 |
Correlation and Regression Analysis | p. 249 |
Correlation Analysis | p. 249 |
Simple Linear Regression Analysis | p. 252 |
Financial Impact Analysis: Net Present Value, Return on Investment, and Payback Period | p. 259 |
Net Present Value | p. 259 |
Return on Investment | p. 262 |
Payback Period | p. 263 |
Financial Impact Analysis Exercise | p. 264 |
Data Collection Efforts | p. 265 |
Planning | p. 265 |
Calculating Sample Size | p. 267 |
Systematic Sampling | p. 272 |
Stratified Sampling | p. 273 |
Block Sampling | p. 274 |
Operational Definition | p. 274 |
Types of Data | p. 275 |
Net Present Value Exercise Answer | p. 277 |
Financial Impact Analysis Exercise Answer | p. 277 |
Index | p. 279 |
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