Six Sigma for Managers

Foreword, Mikel J. Harry xi Preface xiii 1. Introduction to Six Sigma 1 What Is Six Sigma? 1 Evolution of the Six Sigma Fundamentals 2 What Is Sigma? 4 Essentials of the Six Sigma Methodology 7 Focus on Engaging People and Changing Processes 9 Not Only Statistics, but Cultural Changes 10 Six Sigma Is Not ... 11 Manager's Checklist for Chapter 1 13 2. Defining Quality and Measuring Performance 15 Start with Your Customers 16 Understand Your Processes 19 Determine Your Metrics 21 The Essential Six Sigma Formula 24 Quality and Metrics, First and Last 24 Manager's Checklist for Chapter 2 25 3. The Right Way to Implement Six Sigma 27 Six Sigma: The Early Years and Implementation Flaws 27 A More Realistic Approach to Six Sigma 29 Readying the Organization 33 Key Players 35 Executive Leaders and Champions 36 Champions 38 Master Black Belts 39 Black Belts 40 Green Belts 41 Communicate! 42 Train! 43 Infrastructure 44 What to Expect from Outside Consultants 45 Getting Started: The Dos 46 Getting Started: The Don'ts 48 Executive Overview of DMAIC 49 Manager's Checklist for Chapter 3 51 4. Define Phase 53 Define Phase Activities 53 Define the Phase-Gate Review 75 Summary 76 Manager's Checklist for Chapter 4 76 5. Measure Phase 77 Purposes of the Measure Phase 78 Measure Phase Activities 79 Step 1. Map the Process in Detail 81 Step 2. Create a YX Matrix 84 Step 3. Perform a Failure Modes and Effects Analysis (FMEA) 89 Step 4. Conduct a Measurement System Analysis (MSA) 95 Step 5. Determine Process Capability 104 Z Scores and Sigma Shift 111 Measure Phase-Gate Review 113 Manager's Checklist for Chapter 5 114 6. Analyze Phase 115 Analyze Phase Activities 116 Analyze Phase Tools 120 Ascertain and Prioritize Vital Few Causes of Variation 142 Transform the Gaps into Improvement Projects 144 Review the Project with the Champion 145 Conduct an Analyze Phase-Gate Review 145 Manager's Checklist for Chapter 6 146 7. Improve Phase 147 Improve Phase Activities 148 Improve Phase Tools 149 Correlation 149 Regression Analysis 151 Design of Experiments 153 Planning the Experiment (DOE) 155 Conducting the Experiment 165 Running the Experiment 168 Analyzing the Experiment Results 170 Review the Project with the Champion 176 Conduct an Improve Phase-Gate Review 176 Manager's Checklist for Chapter 7 177 8. Control Phase 179 Control Phase Steps and Tools 180 Control Plan 181 Statistical Process Control 182 Control Charts 196 Contingency Plans for Out-of-Control Conditions 196 Minimizing the Potential for Problems-Mistake Proofing 197 Plan for Transfer to Process Owners 199 Communication Plans 202 Review the Project with the Champion 205 Conduct a Control Phase-Gate Review 206 Control Phase Deliverables 206 Summary 207 Manager's Checklist for Chapter 8 208 9. How to Sustain Six Sigma 209 Basic Infrastructure Requirements 210 Communication Plan 211 Company Culture 213 Company Cycles 215 Reinforcement and Control 217 Manager's Checklist for Chapter 9 219 10. Six Sigma Proof Positive 221 Real Final Reports 222 Case Studies 224 Training Agendas 229 Design for Six Sigma 233 The End .. . and the Beginning 235 Manager's Checklist for Chapter 10 236 Index 239