Six Sigma: Advanced Tools for Black Belts and Master Black Belts

428 Pages·2006·4.25 MB·English

by  Loon Ching Tang

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Six Sigma
Advanced Tools for Black Belts and
Master Black Belts
Loon Ching Tang
NationalUniversityofSingapore,Singapore
Thong Ngee Goh
NationalUniversityofSingapore,Singapore
Hong See Yam
SeagateTechnologyInternational,Singapore
Timothy Yoap
FlextronicsInternational,Singapore
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Six Sigma
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Six Sigma
Advanced Tools for Black Belts and
Master Black Belts
Loon Ching Tang
NationalUniversityofSingapore,Singapore
Thong Ngee Goh
NationalUniversityofSingapore,Singapore
Hong See Yam
SeagateTechnologyInternational,Singapore
Timothy Yoap
FlextronicsInternational,Singapore
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LibraryofCongressCataloging-in-PublicationData
Sixsigma:advancedtoolsforblackbeltsandmasterblackbelts/LoonChingTang...[etal.].
p. cm.
Includesbibliographicalreferencesandindex.
ISBN-13:978-0-470-02583-3(cloth:alk.paper)
ISBN-10:0-470-02583-2(cloth:alk.paper)
1.Sixsigma(Qualitycontrolstandard) 2.Totalqualitymanagement. I.Tang,LoonChing.
TS156.S5372006
658.5(cid:3)62--dc22
2006023985
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ISBN-13 978-0-470-02583-3(HB)
ISBN-10 0-470-02583-2(HB)
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Contents
Preface.................................................................................................. xi
PARTA: SIXSIGMA:PAST,PRESENTANDFUTURE
1 SixSigma:APreamble..................................................................... 3
H.S.Yam
1.1 Introduction.............................................................................. 3
1.2 SixSigmaRoadmap:DMAIC....................................................... 4
1.3 SixSigmaOrganization.............................................................. 7
1.4 SixSigmaTraining..................................................................... 8
1.5 SixSigmaProjects...................................................................... 10
1.6 Conclusion............................................................................... 17
References....................................................................................... 17
2 AStrategicAssessmentofSixSigma.................................................. 19
T.N.Goh
2.1 Introduction.............................................................................. 19
2.2 SixSigmaFramework................................................................. 20
2.3 SixSigmaFeatures..................................................................... 21
2.4 SixSigma:ContrastsandPotential............................................... 22
2.5 SixSigma:InherentLimitations.................................................... 23
2.6 SixSigmaintheKnowledgeEconomy.......................................... 25
2.7 SixSigma:ImprovingtheParadigm.............................................. 27
References....................................................................................... 28
3 SixSigmaSWOT............................................................................. 31
T.N.GohandL.C.Tang
3.1 Introduction.............................................................................. 31
3.2 OutlineofSixSigma................................................................... 32
3.3 SWOTAnalysisofSixSigma....................................................... 32
3.4 FurtherThoughts....................................................................... 37
References....................................................................................... 39
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vi Contents
4 TheEssenceofDesignforSixSigma.................................................. 41
L.C.Tang
4.1 Introduction.............................................................................. 41
4.2 TheIDOVRoadmap................................................................... 42
4.3 TheFuture................................................................................ 48
References....................................................................................... 48
5 FortifyingSixSigmawithOR/MSTools............................................. 49
L.C.Tang,T.N.GohandS.W.Lam
5.1 Introduction.............................................................................. 49
5.2 IntegrationofOR/MSintoSixSigmaDeployment.......................... 50
5.3 ANewRoadmapforSixSigmaBlackBeltTraining......................... 52
5.4 CaseStudy:ManpowerResourcePlanning.................................... 58
5.5 Conclusions.............................................................................. 68
References....................................................................................... 68
PARTB: MEASUREPHASE
6 ProcessVariationsandTheirEstimates............................................... 73
L.C.TangandH.S.Yam
6.1 Introduction.............................................................................. 73
6.2 ProcessVariability..................................................................... 76
6.3 NestedDesign........................................................................... 79
References....................................................................................... 83
7 FishboneDiagramsvs.MindMaps.................................................... 85
TimothyYoap
7.1 Introduction.............................................................................. 85
7.2 TheMindMapStepbyStep........................................................ 86
7.3 ComparisonbetweenFishboneDiagramsandMindMaps............... 87
7.4 ConclusionandRecommendations............................................... 91
References....................................................................................... 91
8 CurrentandFutureRealityTrees....................................................... 93
TimothyYoap
8.1 Introduction.............................................................................. 93
8.2 CurrentRealityTree................................................................... 94
8.3 FutureRealityTree(FRT)............................................................ 97
8.4 ComparisonwithCurrentSixSigmaTools..................................... 101
8.5 ConclusionandRecommendations............................................... 105
References....................................................................................... 105
9 ComputingProcessCapabilityIndicesforNonnormalData:AReview
andComparativeStudy.................................................................... 107
L.C.Tang,S.E.ThanandB.W.Ang
9.1 Introduction.............................................................................. 107
9.2 SurrogatePCIsforNonnormalData............................................. 108
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Contents vii
9.3 SimulationStudy....................................................................... 113
9.4 DiscussionofSimulationResults.................................................. 127
9.5 Conclusion............................................................................... 128
References....................................................................................... 129
10 ProcessCapabilityAnalysisforNon-NormalDatawithMINITAB........ 131
TimothyYoap
10.1 Introduction............................................................................ 131
10.2 IllustrationoftheTwoMethodologiesUsingaCaseStudyDataSet... 132
10.3 AFurtherCaseStudy............................................................... 141
10.4 MonteCarloSimulation............................................................ 145
10.5 Summary................................................................................ 149
References....................................................................................... 149
PARTC: ANALYZEPHASE
11 Goodness-of-FitTestsforNormality................................................... 153
L.C.TangandS.W.Lam
11.1 Introduction............................................................................ 153
11.2 UnderlyingPrinciplesofGoodness-of-FitTests............................. 154
11.3 PearsonChi-SquareTest............................................................ 155
11.4 EmpiricalDistributionFunctionBasedApproaches....................... 157
11.5 Regression-BasedApproaches.................................................... 163
11.6 Fisher’sCumulantTests............................................................ 167
11.7 Conclusion.............................................................................. 170
References....................................................................................... 170
12 IntroductiontotheAnalysisofCategoricalData.................................. 171
L.C.TangandS.W.Lam
12.1 Introduction............................................................................ 171
12.2 ContingencyTableApproach..................................................... 173
12.3 CaseStudy.............................................................................. 176
12.4 LogisticRegressionApproach.................................................... 181
12.5 Conclusion.............................................................................. 193
References....................................................................................... 193
13 AGraphicalApproachtoObtainingConfidenceLimitsofC .............. 195
pk
L.C.Tang,S.E.ThanandB.W.Ang
13.1 Introduction............................................................................ 196
13.2 GraphingC ,kandp................................................................. 197
p
13.3 ConfidenceLimitsfork............................................................. 199
13.4 ConfidenceLimitsForC ......................................................... 201
pk
13.5 ASimulationStudy.................................................................. 203
13.6 IllustrativeExamples................................................................ 206
13.7 ComparisonwithBootstrapConfidenceLimits............................. 207
13.8 Conclusions............................................................................ 209
References....................................................................................... 210