Lean Six Sigma For Dummies

362 Pages·2012·5.52 MB·English

by  John Morgan

®
Lean Six Sigma For Dummies , 2nd
Edition
Visit www.dummies.com/cheatsheet/leansixsigmauk
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Table of Contents
Introduction
About This Book
Conventions Used in This Book
Foolish Assumptions
How This Book Is Organised
Part I: Lean Six Sigma Basics
Part II: Working with Lean Six Sigma
Part III: Assessing Performance
Part IV: Improving the Processes
Part V: Deploying Lean Six Sigma
Part VI: The Part of Tens
Icons Used In This Book
Where to Go From Here
Part I: Lean Six Sigma Basics
Chapter 1: Defining Lean Six Sigma
Introducing Lean Thinking
Bringing on the basics of Lean
Perusing the principles of Lean thinking
Sussing Six Sigma
Considering the core of Six Sigma
Calculating process sigma values
Meeting the major points of Six Sigma
Chapter 2: Understanding the Principles of Lean Six
Sigma
Considering the Key Principles of Lean Six
Sigma
Improving Existing Processes: Introducing
DMAIC
Defining your project
Measuring how the work is done
Analysing your process
Improving your process
Coming up with a control plan
Reviewing Your DMAIC Phases
Taking a Pragmatic Approach
Part II: Working with Lean Six Sigma
Chapter 3: Identifying Your Customers
Understanding the Process Basics
Pinpointing the elements of a process
Identifying internal and external
customers
Getting a High-Level Picture
Drawing a high-level process map
Segmenting customers
Chapter 4: Understanding Your Customers’ Needs
Can You Kano?
Obtaining the Voice of the Customer
Taking an outside-in view
Segmenting your customers
Prioritising your customers
Researching the Requirements
Interviewing your customers
Focusing on focus groups
Considering customer surveys
Using observations
Avoiding Bias
Considering Critical To Quality Customer
Requirements
Establishing the Real CTQs
Prioritising the requirements
Measuring performance using customer-
focused measures
Chapter 5: Determining the Chain of Events
Finding Out How the Work Gets Done
Practising process stapling
Drawing spaghetti diagrams
Painting a Picture of the Process
Keeping things simple
Developing a deployment flowchart
Seeing the value in a value stream map
Identifying moments of truth
Part III: Assessing Performance
Chapter 6: Gathering Information
Managing by Fact
Realising the importance of good data
Reviewing what you currently measure
Deciding what to measure
Developing a Data Collection Plan
Beginning with output measures
Creating clear definitions
Agreeing rules to ensure valid and
consistent data
Collecting the data
Identifying ways to improve your
approach
An Introduction to Sampling
Process sampling
Population sampling
Chapter 7: Presenting Your Data
Delving into Different Types of Variation
Understanding natural variation
Spotlighting special cause variation
Distinguishing between variation types
Avoiding tampering
Displaying data differently
Recognising the Importance of Control Charts
Creating a control chart
Unearthing unusual features
Choosing the right control chart
Examining the state of your processes
Considering the capability of your
processes
Additional ways to present and analyse
your data
Testing Your Theories
Chapter 8: Analysing What’s Affecting Performance
Unearthing the Usual Suspects
Generating your list of suspects
Investigating the suspects and getting the
facts
Getting a Balance of Measures
Connecting things up
Proving your point
Seeing the point
Assessing your effectiveness
Part IV: Improving the Processes
Chapter 9: Identifying Value-Added Steps and Waste
Interpreting Value-Added
Providing a common definition
Carrying out a value-added analysis
Assessing opportunity
Looking at the Seven Wastes
Owning up to overproduction
Playing the waiting game
Troubling over transportation
Picking on processing
Investigating inventory
Moving on motion
Coping with correction
Looking Beyond the Seven Wastes
Wasting people’s potential
Going green
Considering customer perspectives
Focusing on the Vital Few
Chapter 10: Discovering the Opportunity for
Prevention
Keeping Things Neat and Tidy
Introducing the Five Ss
Carrying out a red-tag exercise
Using visual management
Looking at Prevention Tools and Techniques
Introducing Jidoka
Reducing risk with Failure Mode Effects
Analysis (FMEA)
Error proofing your processes
Profiting from Preventive Maintenance
Avoiding Peaks and Troughs
Introducing Heijunka
Spreading the load
Carrying out work in a standard way
Chapter 11: Identifying and Tackling Bottlenecks
Applying the Theory of Constraints
Identifying the weakest link
Improving the process flow
Building a buffer
Managing the Production Cycle
Using pull rather than push production
Moving to single piece flow
Recognising the problem with batches
Looking at Your Layout
Identifying wasted movement
Using cell manufacturing techniques
Identifying product families
Chapter 12: Introducing Design for Six Sigma
Introducing DfSS
Introducing DMADV
Defining What Needs Designing