Implementing Six Sigma (eBook)

Forrest W. Breyfogle III is the founder and President of Smarter Solutions, Inc., a company specializing in training andconsulting in Six Sigma methodologies. He is the author of Statistical Methods for Testing, Development, and Manufacturing and Implementing Six Sigma and coauthor of Managing Six Sigma, all published by Wiley.

PREFACE.

PART I: S¯4/IEE DEPLOYMENT AND DEFINE PHASE FROMDMAIC.

1. Six Sigma Overview and S¯4/IEEE Implementation.

2. Voice of the Customer and the S¯4/IEEE DefinePhase.

PART II: S¯4/IEE MEASURE PHASE FROM DMAIC.

3. Measurement and the S¯4/IEEE Measurement Phase.

4. Process Flow Charting/Process Mapping.

5. Basic Tools.

6. Probability.

7. Overview of Distributions and Statistical Processes.

8. Probability and Hazard Plotting.

9. Six Sigma Measurements.

10. Basic Control Charts.

11. Process Capability and Process Performance Metrics.

12. Measurement Systems Analysis.

13. Cause-and-Effect Matrix and Quality Function Deployment.

14. FMEA (Failure Mode and Effects Analysis).

PART III: S¯4/IEE ANALYZE PHASE FROM DMAIC (OR PASSIVEANALYSIS PHASE).

15. Visualization of Data.

16. Confidence Intervals and Hypothesis Tests.

17. Inferences: Continuous Response.

18. Inference: Attribute (Pass/Fail) Response.

19. Comparison Tests: Continuous Response.

20. Comparison Tests: Attribute (Pass/Fail) Response.

21. Bootstrapping.

22. Variance Components.

23. Correlation and Simple Linear Regression.

24. Single-Factor (One-Way) Analysis of Variance (ANOVA) andAnalysis of Means (ANOM).

25. Two-Factor (Two-Way) Analysis of Variance.

26. Multiple Regression, Logistic Regression, and IndicatorVariables.

PART IV: S¯4/IEE IMPROVE PHASE FROM DMAIC (ORPROACTIVE TESTING PHASE).

27. Benefiting from Design of Experiments (DOE).

28. Understanding the Creation of Full and Fractional Factorial2¯K DOEs.

29. Planning 2¯K DOEs.

30. Design and Analysis of 2¯K DOEs.

31. Other DOE Considerations.

32. Robust DOE.

33. Response Surface Methodology.

PART V: S¯4/IEE CONTROL PHASE FROM DMAIC ANDAPPLICATION EXAMPLES.

34. Short-Run and Target Control Charts.

35. Control Charting Alternatives.

36. Exponentially Weighted Moving Average (EWMA) and EngineeringProcess Control (EPC).

37. Pre-Control Charts.

38. Control, Plan, Poka-Yoke, Realistic Tolerancing, and ProjectCompletion.

39. Reliability Testing/Assessment: Overview.

40. Reliability Testing/Assessment: Repairable System.

41. Reliability Testing/Assessment: Nonrepairable Devices.

42. Pass/Fall Functional Testing.

43. S¯4/IEEE Application Examples.

PART VI: S¯4/IEE LEAN AND THEORY OF CONSTRAINTS.

44. Lean and Its Integration with S¯4/IEEE .

45. Integrating of Theory of Constraints (TOC) inS¯4 /IEE.

PART VII: DFSS AND 21-STEP INTEGRATION OF THE TOOLS.

46. Manufacturing Applications and A 21-Step Integration of theTools.

47. Service/Transactional Applications and A 21-Step Integrationof the Tools.

48. DFSS Overview and Tools.

49. Product DFSS.

50. Process DFSS.

PART VIII: MANAGEMENT OF INFRASTRUCTURE AND TEAM EXECUTION.

51. Change Management.

52. Project Management and Financial Analysis.

53. Team Effectiveness.

54. Creativity.

55. Alignment of Management Initiatives and Strategies withS¯4/IEEE .

Appendix A. Supplemental Information.

Appendix B. Equations for the Distributions.

Appendix C. Mathematical Relationships.

Appendix D. DOE Supplement.

Appendix E. Reference Tables.

List of Symbols.

Glossary.

References.

Index.

"The book is process oriented rather than tool oriented. This makes
it refreshing and useful. This is a book every reliability engineer
should own." (Reliability Review; 12/08)

"An excellent reference book that should be on every individual
involved in Six Sigma or even just quality assurance/quality
improvement." (TQM Magazine)

"...a useful guide for both academia and organizations...useful
source of reference for researchers...an excellent reference
book..." (The TQM Magazine, Vol 15(6) 2003)
2004 Crosby Medal Winner